Harley Davidson 2008 Touring Models. Service Manual - page 42

24. FLTR Only:

On left side of motorcycle, remove screw (with flat
washer) to remove passenger seat strap and
saddlebag front mounting bracket. Remove screw
and chrome frame tube cover.

Cut cable strap to release radio antenna cable from
shoulder of upper frame tube (just in front of air valve
mounting bracket). Cut cable strap to release radio
antenna cable from slotted hole in rear fender support.

At bottom of radio antenna bracket, rotate knurled
ring to disconnect radio antenna cable connector [29].

Draw radio antenna cable forward and then out
through opening at rear of left side caddy.

25. Pull accessory connector [4] and B+ connector [160] out

through opening at rear of left side caddy.

26. Pull back boot at top of starter housing and remove flange

nut and main power cable ring terminal from post. Draw
main power cable into battery tray and then out through
opening at rear of left side caddy.

27. Remove starter. See

5.2 STARTER

28. Disconnect VSS connector [65], 3-place Delphi, at top of

transmission case.

29. Remove two elbow connectors from neutral switch posts.

30. Disconnect rear O2 sensor connector [137], 2-place Amp

(Tyco).

31. Carefully pull VSS, neutral switch, rear O2 sensor and

starter solenoid conduit and connectors up through
opening at front of battery tray (inboard of right side finger),
and then feed branch out through opening at rear of left
side caddy.

32. ABS Equipped Only:

Disconnect ABS module connector [166], 20-place
Molex.

Pull anchor on rear wheel speed sensor connector
[168], 2-place Amp (Tyco), from hole in right side
caddy. Disconnect connector.

Alternately feed conduit and connectors into battery
tray and then out through opening at rear of left side
caddy.

33. Disconnect voltage regulator as follows:

Loosen locknuts on studs of lower frame cross-
member.

Lift voltage regulator and release voltage regulator
connector conduit from P-clip at front of right side leg
of voltage regulator.

Pull away locking latch and remove socket of voltage
regulator connector [77], 2-place Lyall, at bottom right
side of voltage regulator.

34. Locate CKP sensor connector [79], 2-place Deutsch, fixed

to front caddy at bottom of lower frame crossmember.
Push connector toward right side of motorcycle to disen-
gage attachment clip from T-stud. Disconnect connector.

35. Push anchor on jiffy stand interlock sensor connector [133],

3-place Molex, from hole in front caddy. Disconnect con-
nector.

36. Locate oil pressure switch/sender at front right side of

crankcase. On FLHR/C models, pull elbow from post of
oil pressure switch. On FLHX, FLHT/C/U and FLTR
models, remove Delphi connector from oil pressure sender.

37. Cut cable strap and disconnect front O2 sensor connector

[138], 2-place Amp (Tyco), at back of cross brace between
front frame downtubes. Cut cable straps to release conduit
from right front frame downtube.

38. Cut cable strap to free main harness conduit from inboard

side of rear brake pedal weldment.

39. Cut cable straps to free rear brake line and main harness

conduit from two rubber saddles anchored on T-studs at
top of lower frame tube.

40. Pull two socket terminals from spade contacts on rear

brake light switch. Cut cable strap to free rear brake light
switch wires from lower frame tube.

41. Cut cable strap at rear of rear brake light switch bracket

to release main harness conduit from middle frame
downtube.

42. Pull anchored cable strap from hole in middle frame

downtube (adjacent to rear swingarm bracket) to release
main harness conduit.

43. Disconnect active exhaust valve actuator connector [179],

5-place Amp (Tyco). If active exhaust valve actuator is not
provided, disconnect unused socket housing from mock
pin housing on right side of battery tray.

44. Carefully pull rear brake light switch, oil pressure

switch/sender, CKP sensor, jiffy stand interlock sensor,
voltage regulator and front O2 sensor conduit and con-
nectors rearward, and then up through opening at front of
battery tray (outboard of right side finger). Feed branch
into battery tray pulling it out through opening at rear of
left side caddy.

45. While pulling left side caddy away from motorcycle, feed

rear end of wire trough out through opening between frame
downtubes.

2008 Touring Service: Electrical 8-87

sm05153

Front fuel injector [84]

TCA [211]

T-MAP sensor [80]

Rear fuel injector [85]

Figure 8-105. Induction Module Assembly (Top View)

INSTALLATION: ALL MODELS (PART 1)

Standing on left side of motorcycle, feed front end of wire
trough in through opening between frame downtubes, and
then pull up and out through opening at top of battery tray.
Lay wire trough on top of frame backbone.

Push anchor pins at rear of wire trough into holes in frame
backbone.

Locate branch of main harness terminating in the active
exhaust valve actuator, rear brake light switch, oil pressure
switch/sender, CKP sensor, jiffy stand interlock sensor,
voltage regulator and front O2 sensor connectors. Feed
harness in through opening at rear of left side caddy, and
then down through opening at front of battery tray (out-
board of right side finger) to bottom of frame downtube.
Route harness to front of motorcycle following inboard
side of lower frame tube.

Locate branch terminating in the VSS, neutral switch, rear
O2 sensor and starter solenoid connectors. Feed harness
in through opening at rear of left side caddy, and then
down through opening at front of battery tray (inboard of
right side finger) to top of transmission.

If ABS equipped, locate branch terminating in the ABS
module and rear wheel speed sensor connectors. Feed
harness in through opening at rear of left side caddy and
then pull out through opening at right side of battery tray.

Locate branch terminating in the Tour-Pak lights and radio
antenna cable connectors. Feed harness in through
opening at rear of left side caddy and then pull up and out
through opening between frame crossmember and front
of rear fender. Lay harness across left side of rear fender.

FLHTCU Only:

Locate branch of audio harness terminating in the CB
antenna cable, console and rear speaker/passenger
controls connectors. Feed harness in through opening
at rear of left side caddy and then pull up and out
through opening at top of battery tray and lay across
right side of rear fender.

Locate branch terminating in the rear headset
receptacle and rear speaker/passenger controls
connector. Feed harness in through opening at rear
of left side caddy and then pull up and out through
opening at top of battery tray and lay across left side
of rear fender.

Feeding main power cable ring terminal and B+,
accessory, rear fender lights, ignition keyswitch relay, and
TSM/HFSM connectors and conduit inboard, seat left side
caddy on weldment between frame downtubes.

While pulling up on battery tray, push on left side caddy
until tab engages slot on battery tray.

10. Start front screw to fasten left side caddy to battery tray.

Start rear screw to fasten caddy to frame weldment.
Alternately tighten screws to 72-96 in-lbs (8.1-10.9 Nm).

NOTE

If equipped, push two retaining latches forward and slide siren
into compartment at front of left side caddy. Connect connector.

11. If loosened, tighten screw (with lifting strap) in middle finger

of battery tray to 72-96 in-lbs (8.1-10.9 Nm).

12. Move main power cable ring terminal to front of battery

tray and then feed down through opening (inboard of left
side finger) to top of transmission.

13. Tuck B+ and accessory connectors and conduit into corner

at front of battery tray. Move rear fender lights, ignition
keyswitch relay, and TSM/HFSM connectors and conduit
under frame crossmember at rear of battery tray.

14. Connect VSS connector [65], 3-place Delphi, at top of

transmission case.

15. Install two elbow connectors onto neutral switch posts.

16. Install starter. See

5.2 STARTER

17. Connect rear O2 sensor connector [137], 2-place Amp

(Tyco), and tuck under chrome starter cover.

18. Install anchored cable strap in hole of frame downtube

(inboard of rear swingarm bracket) to secure main harness
conduit. See

Figure 8-106

19. Install new cable strap at rear of rear brake light switch

bracket capturing main harness conduit and frame down-
tube.

20. Install two socket terminals onto spade contacts of rear

brake light switch. Install new cable strap to secure rear
brake light switch wires to lower frame tube.

21. Seat rear brake line on two rubber saddles anchored on

T-studs at top of lower frame tube. Engaging slots in
rubber saddles, install new cable straps capturing rear
brake line, main harness conduit and lower frame tube.

8-88 2008 Touring Service: Electrical

NOTE

Replace rubber saddles if damaged, deteriorated or missing.
With the slotted side up, push hole in rubber saddle over T-
stud to install.

22. Route main harness conduit inboard of rear brake pedal

weldment. Capturing main harness conduit and lower
frame tube, install new cable strap through opening in
weldment.

23. Connect front O2 sensor connector [138], 2-place Amp

(Tyco). Install new cable strap to secure connector to back
of cross brace between front frame downtubes. Install new
cable straps to secure conduit to right front frame down-
tube.

24. Connect voltage regulator as follows:

Route voltage regulator connector [77], 2-place Lyall,
upward at front of lower frame crossmember capturing
conduit in P-clip at front of right side leg of voltage
regulator.

Install socket at bottom right side of voltage regulator.
Push against locking latch until socket is fully
engaged.

Alternately tighten locknuts on studs of lower frame
crossmember to 70-100 in-lbs (7.9-11.3 Nm).

25. Connect CKP sensor connector [79]. Place large end of

slot on attachment clip over T-stud on front caddy at
bottom of lower frame crossmember. Push connector
toward left side of motorcycle to engage small end of slot.

26. Connect jiffy stand interlock sensor connector [133], 3-

place Molex. Push anchor on connector into hole in front
caddy.

27. Install oil pressure switch/sender connector at front right

side of crankcase. On FLHR/C models, install elbow con-
nector on post terminal. On FLHX, FLHT/C/U and FLTR
models, install 4-place Delphi connector.

28. Connect active exhaust valve actuator connector [179],

5-place Amp (Tyco). If active exhaust valve actuator is not
provided, connect unused socket housing to mock pin
housing on right side of battery tray.

29. ABS Equipped Only:

Connect ABS module connector [166], 20-place
Molex.

Connect rear wheel speed sensor connector [168],
2-place Amp (Tyco). Install anchor on rear wheel
speed sensor connector into hole in right side caddy.

30. FLHX Only:

Feed radio antenna cable and rear facia lamp wires
rearward following inboard side of upper frame tube.

Mate pin and socket housings of rear facia lamp
connector [12], 3-place Multilock.

Install new cable strap to secure rear facia lamp wires
and radio antenna cable to shoulder of upper frame
tube (just in front of air valve mounting bracket).

Using slotted hole, install new cable strap to secure
rear facia lamp wires and radio antenna cable to rear
fender support.

At bottom of radio antenna bracket, rotate knurled
ring to connect radio antenna cable connector [29].

Install chrome frame tube cover on frame tube. Install
screw and tighten to 25-40 in-lbs (2.8-4.5 Nm). Install
screw (with flat washer) to fasten saddlebag front
mounting bracket and passenger seat strap to chrome
frame tube cover.

31. FLHTC/U Only:

Feed Tour-Pak lights and radio antenna cable con-
nectors and conduit through hole at front of Tour-Pak.
Capture cable and conduit in grommet. Install
grommet in hole with the larger OD facing inside.

Connect Tour-Pak lights connector [12], 3-place
Multilock.

Rotate knurled ring to connect radio antenna cable
connector [29]. Capture cable in two adhesive clips
at bottom of Tour-Pak.

On FLHTCU models, install bulb socket of left side
wrap-around light.

Install new cable strap to secure main harness con-
duit to luggage rack rail.

Connect audio harness on FLHTCU models. See

8.37 AUDIO HARNESS: FLHTCU

, steps 8-19.

Proceed as follows:

FLHTC: Install rubber mat in Tour-Pak.

FLHTCU: Install molded liner in Tour-Pak. Install map
pocket and secure using acorn nuts (with flat
washers).

2008 Touring Service: Electrical 8-89

32. FLTR Only:

Feed radio antenna cable and 3-place Multilock con-
nector (unused) rearward following inboard side of
upper frame tube.

Install new cable strap to secure radio antenna cable
to shoulder of upper frame tube (just in front of air
valve mounting bracket).

Using slotted hole, install new cable strap to secure
radio antenna cable to rear fender support.

At bottom of radio antenna bracket, rotate knurled
ring to connect radio antenna cable connector [29].

Install chrome frame tube cover on frame tube. Install
screw and tighten to 25-40 in-lbs (2.8-4.5 Nm). Install
screw (with flat washer) to fasten saddlebag front
mounting bracket and passenger seat strap to chrome
frame tube cover.

33. Routing connector up between frame crossmember and

rear fender, connect rear fender lights connector [7], 8-
place Multilock, and attach to anchor at front of rear fender.

34. Feed ignition keyswitch relay with rubber boot up through

hole on left side of frame crossmember. Install anchors
on rubber boot into holes in frame crossmember.

35. Feed TSM/HFSM connector [30] up through hole on right

side of frame crossmember and connect to module. If
present, feed HFSM antenna down through same hole,
and then pull back up and out through empty slot of rubber
boot on left side. Install module into hole in crossmember
and install spring clip.

36. FLHR/C Only:

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

Connect instrument console connector [20], 16-place
Molex, inboard of left upper frame tube.

Connect ignition switch jumper harness connector
[222], 4-place Packard. Install anchor on connector
into hole in left side of battery tray.

37. Move ECM (with attached top caddy) to motorcycle. Con-

nect ECM connector [78].

38. Install two main harness ground ring terminals (with orange

tape) onto front ground stud on left side of frame back-
bone. Install flange nut (10 mm) and tighten to 50-90 in-
lbs (5.7-10.2 Nm).

39. Install main harness ground ring terminal (without orange

tape) onto rear ground stud. Route chassis ground cable
forward along left side of wire trough and install ring ter-
minal on rear ground stud. Install flange nut (10 mm) and
tighten to 50-90 in-lbs (5.7-10.2 Nm).

40. Install connectors to induction module as follows:

Install T-MAP sensor connector [80].

Install TCA connector [211]. Install new anchored
cable strap in hole at front right side of induction
module. Tighten cable strap capturing connector
conduit.

Install front fuel injector connector [84] and rear fuel
injector connector [85].

41. Install purge solenoid connector [95]. If purge solenoid is

not provided, install anchored cable strap on socket
housing into hole in wire trough (below breakout compart-
ment).

42. Install ET sensor connector [90] at back of front cylinder.

Pull boot over sensor to keep out dirt and debris.

43. Install elbow terminals onto horn spade contacts. Capture

conduit in J-clamp. Install screw (with flat washer) to fasten
horn bracket to rear cylinder head. Alternately tighten front
and rear horn bracket screws to 35-40 ft-lbs (48-54 Nm).

44. Install ignition coil connector [83].

45. On ABS equipped motorcycles, secure brake line as fol-

lows:

Press brake lines into channel at front of wire trough.

Position brake lines on narrow ledge at side of wire
trough. At rear of ledge, install new cable strap to
secure brake lines to wire trough.

Install three double-sided clips to secure brake line
from master cylinder to brake line to front calipers.
Place the clips as follows: in front of ignition coil
bracket, above wire trough breakouts, and in front of
threaded boss for the rear fuel tank bracket bolt.

46. Install backplate and air cleaner. See

4.3 AIR CLEANER

ASSEMBLY

NOTE

Depending upon model, continue procedure at

8.34 MAIN

WIRING HARNESS, Installation: FLHR/C (Part 2)

8.34 MAIN

WIRING HARNESS, Installation: FLHX, FLHT/C/U (Part 2)

8.34 MAIN WIRING HARNESS, Installation: FLTR (Part 2)

8-90 2008 Touring Service: Electrical

sm05223

Captures main harness and lower frame tube

Captures rear brake line, main harness and lower frame tube

Captures rear brake light switch wires, main harness and lower frame tube

Captures main harness and frame downtube

Captures main harness

Figure 8-106. Cable Strap Locations (Right Side View)

sm02960

Figure 8-107. Capture Radio Antenna Cable (FLTR)

sm02961

Figure 8-108. Capture Radio Antenna Cable (FLHX)

2008 Touring Service: Electrical 8-91

INSTALLATION: FLHR/C (PART 2)

Route front right section of main harness forward along
right side of steering head and into headlamp nacelle.

See

Figure 8-103

. Reaching inside headlamp nacelle,

connect connectors and install onto their retaining devices,
if present:

Auxiliary lamps [73], 2-place Multilock (white).

Auxiliary lamps switch [109], 4-place Amp.

Right handlebar switches [22], 6-place Molex (black);
T-stud on fork stem nut lockplate (right side)

Cruise set/resume switch [159], 3-place Molex (black);
used on FLHRC only.

Twist grip sensor jumper harness [204], 6-place Molex
(black).

Install P-clamp and screw to fasten main harness conduit
to right side of steering head.

Route front left section of main harness forward along left
side of steering head and into headlamp nacelle.

Reaching inside headlamp nacelle, connect connectors
and install onto their retaining devices, if present:

Front fender tip lamp jumper harness [32], 2-place
Multilock (black); used on FLHR only.

Accessory switch [67], 4-place Amp.

Front turn signal lamps [31], 6-place Multilock;
anchored in hole of fork stem nut lock plate (left side).

Left handlebar switches [24], 8-place Molex (gray);
T-stud on fork stem nut lockplate (left side).

Cruise on/off switch [158], 3-place Molex (gray); used
on FLHRC only.

Front wheel speed sensor [167], 2-place Amp (Tyco);
used on ABS equipped motorcycles only.

Install P-clamp and screw to fasten main harness conduit
to left side of steering head.

Install headlamp assembly. See

8.9 HEADLAMP: ALL

EXCEPT FLTR

NOTE

Continue procedure at

8.34 MAIN WIRING HARNESS,

Installation: All Models (Part 3)

INSTALLATION: FLHX, FLHT/C/U (PART 2)

Route front right section of main harness forward along
right side of steering head and then under fairing cap to
front of inner fairing.

Proceed as follows:

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

Using oblong holes in fairing brackets and a long
shank ball end socket (Snap-on® FABL6E), install
four 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 anchor on ignition switch connector conduit
into hole at bottom right corner of radio.

See

Figure 8-104

. Connect connectors and install onto

their retaining devices, if present.

Twist grip sensor jumper harness [204], 6-place Molex
(black); T-stud on right fairing support brace (inboard
side).

Main to interconnect harness [1], 16-place Molex
(black); anchor in hole of right radio support bracket.

Main to interconnect harness [15], 4-place Packard
(black); anchored in hole at front of right fairing
bracket.

Radio antenna cable connector [51]; back of radio
(left side).

Using oval shaped hole at side of right fairing bracket,
install new cable strap capturing conduit of main to inter-
connect harness connector [1], main to interconnect har-
ness connector [15], right handlebar switch connector [22]
and radio connector [27].

Install screw and P-clamp to fasten main harness to right
side of steering head.

Route front left section of main harness (and audio harness
on FLHTCU) forward along left side of steering head and
then under fairing cap to front of inner fairing.

Connect connectors and install onto their retaining devices,
if present.

Main to interconnect harness [2], 12-place Molex
(gray); anchor in hole of left radio support bracket.

Front wheel speed sensor [167], 2-place Amp (Tyco);
below upper fork bracket (left side); used on ABS
equipped motorcycles only.

Using round hole at side of left fairing bracket, install new
cable strap capturing conduit of main to interconnect har-
ness connector [2], left handlebar switch connector [24]
and headlamp connector [38].

Connect audio harness on FLHTCU models. See

8.37 AUDIO HARNESS: FLHTCU

, step 7.

10. Install screw and P-clamp to fasten main harness (and

audio harness on FLHTCU) to left side of steering head.

11. Install outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

NOTE

Continue procedure at

8.34 MAIN WIRING HARNESS,

Installation: All Models (Part 3)

8-92 2008 Touring Service: Electrical

INSTALLATION: FLTR (PART 2)

Install inner fairing. See

2.42 INNER FAIRING: FLTR

NOTE

Continue procedure at

8.34 MAIN WIRING HARNESS,

Installation: All Models (Part 3)

INSTALLATION: ALL MODELS (PART 3)

Install side covers.

Install saddlebags. See

2.27 SADDLEBAGS

Install fuel tank. See

4.4 FUEL TANK

Install battery. See

1.16 BATTERY MAINTENANCE

2008 Touring Service: Electrical 8-93

8.35

INTERCONNECT HARNESS

FLHX, FLHT/C/U

Removal

NOTE

When referencing inner fairing locations, the term "fairing
bracket" refers to either the left or right vertical support, while
the term "support brace" refers to either the left or right hori-
zontal support.

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

Remove outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

Release anchor on convoluted tubing of interconnect
harness from lower ear of speedometer bracket. For best
results, squeeze anchor with needle nose pliers before
pulling from hole in ear. See

Figure 8-109

Cut cable strap to release convoluted tubing of headlamp
connector [38] and conduit of main to interconnect harness
connector [2] and left handlebar switch connector [24] from
left fairing bracket.

Remove anchor on convoluted tubing of headlamp con-
nector [38] from hole at front of left fairing bracket.

Cut cable strap to release convoluted tubing of radio con-
nector [27] and conduit of main to interconnect harness
connector [1], main to interconnect harness connector [15]
and right handlebar switch connector [22] from right fairing
bracket.

See

Figure 8-110

. Disconnect connectors and remove

from their retaining devices, if present.

Left front turn signal/auxiliary lamp [31L], 4-place
Multilock (black); T-stud on left fairing support brace
(outboard side).

Left handlebar switches [24], 16-place Molex (gray);
T-stud on left fairing support brace (inboard side).

Main to interconnect harness [2], 12-place Molex
(gray); anchor in hole of left radio support bracket.

Audio to interconnect harness [6], if present; 6-place
Deutsch (black); left side of radio.

Indicator lights [21]; 10-place Multilock (black); above
radio (between speedometer and tachometer gauges).

Speedometer [39]; 12-place Packard; back of
speedometer. Unthread rubber boot from odometer
reset switch and pull switch from hole in inner fairing.

Tachometer [108]; 12-place Packard; back of tacho-
meter.

Main to interconnect harness [1], 16-place Molex
(black); anchor in hole of right radio support bracket.

Right handlebar switches [22], 12-place Molex (black);
T-stud on right fairing support brace (middle).

Right front turn signal/auxiliary lamp [31R], 4-place
Multilocks (black); T-stud on right fairing support brace
(outboard side).

Main to interconnect harness [15], 4-place Packard
(black); anchored in hole at front of right fairing
bracket.

Fairing cap switches [105], 12-place Multilock (black);
top of upper fork bracket (right side).

m. Radio [27], 23-place Amp (black); back of radio (right

side).

Front fender tip lamp jumper harness [32], if present;
2-place Multilock (black); below upper fork bracket
(left side).

Ambient temperature sensor [107], if present; 3-place
Multilock (black); anchored in hole on left side of
steering head.

See

Figure 8-111

. Remove left side connectors from spade

contacts as follows:

Cigarette lighter [132].

Left front speaker [35].

Fuel gauge [117] and lamp [116].

Air temperature gauge [115] and lamp [114], if
present.

Feed left front turn signal/auxiliary lamp [31L], left
handlebar switch [24], left side speaker, fuel gauge, air
temperature gauge (if present), and cigarette lighter con-
duit and connectors to mid section of inner fairing (area
between left and right fairing brackets).

8-94 2008 Touring Service: Electrical

10. Pull harness ground socket terminal from spade contact

fastened to top of upper fork bracket (left side).

11. Remove right side connectors from spade contacts as

follows:

Right front speaker [34].

Voltmeter gauge [111] and lamp [110].

Oil pressure gauge [113] and lamp [112], if present.

12. Feed right front turn signal/auxiliary lamp [31R], right

handlebar switch [22], right side speaker, voltmeter gauge,
and oil pressure gauge (if present) conduit and connectors
to mid section of inner fairing (area between left and right
fairing brackets).

13. Remove interconnect harness from motorcycle.

sm03707

Figure 8-109. Anchor Interconnect Harness in Ear of

Speedometer Bracket

2008 Touring Service: Electrical 8-95

sm05163

Left front turn signal/auxiliary lamp [31L]

Main to interconnect harness [1]

10.

Main to interconnect harness [2]

Right front turn signal/auxiliary lamp [31R]

11.

Front fender tip lamp [32]

Audio to interconnect harness [6]

12.

Main to interconnect harness [15]

Headlamp [38]

13.

Speedometer gauge [39]

Indicator lights [21]

14.

Right handlebar switches [22]

Fairing cap switches [105]

15.

Tachometer gauge [108]

Left handlebar switches [24]

Radio [27]

Figure 8-110. Inner Fairing- Interconnect Harness Connectors (FLHX, FLHT/C/U)

8-96 2008 Touring Service: Electrical

sm05162

Air temperature gauge [115] and lamp [114]

Right front speaker [34]

Left front speaker [35]

Fuel gauge [117] and lamp [116]

Cigarette lighter [132]

Voltmeter gauge [111] and lamp [110]

Oil pressure gauge [113] and lamp [112]

Figure 8-111. Inner Fairing- Interconnect Harness Connectors (FLHX, FLHT/C/U)

Installation

NOTE

Center interconnect harness on top of radio (or storage
box). To verify proper orientation, be sure that convoluted
tubing of headlamp connector [38] is on left side of
motorcycle, while conduit of fairing cap switch connector
[105] is on the right.

From mid section of inner fairing (area between left and
right fairing brackets), feed left side speaker, fuel gauge,
air temperature gauge (if present), cigarette lighter, left
front turn signal/auxiliary lamp [31L], and left handlebar
switch [24] connectors and conduit behind left fairing
bracket to area of left support brace.

From mid section of inner fairing (area between left and
right fairing brackets), feed right side speaker, voltmeter
gauge, oil pressure gauge (if present), right front turn
signal/auxiliary lamp [31R], and right handlebar switch [22]
connectors and conduit behind right fairing bracket to area
of right support brace.

Install anchor on convoluted tubing of interconnect harness
into lower ear of speedometer bracket.

See

Figure 8-111

. Install left side connectors onto spade

contacts as follows:

Air temperature gauge [115] and lamp [114], if
present; identified by black tape.

Fuel gauge [117] and lamp [116]; identified by orange
tape.

Left front speaker [35].

Cigarette lighter [132]; connect the orange/white wire
socket terminal to the socket spade contact, the black
wire socket terminal to the shell contact.

2008 Touring Service: Electrical 8-97

Push harness ground socket terminal onto spade contact
fastened to top of upper fork bracket (left side).

Install right side connectors onto spade contacts as fol-
lows:

Oil pressure gauge [113] and lamp [112], if present;
identified by black tape.

Voltmeter gauge [111] and lamp [110]; identified by
orange tape.

Right front speaker [34].

See

Figure 8-110

. Connect connectors and install onto

their retaining devices, if present.

Left front turn signal/auxiliary lamp [31L], 4-place
Multilock (black); T-stud on left fairing support brace
(outboard side).

Left handlebar switches [24], 16-place Molex (gray);
T-stud on left fairing support brace (inboard side).

Main to interconnect harness [2], 12-place Molex
(gray); anchor in hole of left radio support bracket.

Audio to interconnect harness [6], if present; 6-place
Deutsch (black); left side of radio.

Indicator lights [21]; 10-place Multilock (black); above
radio (between speedometer and tachometer gauges).

Speedometer [39]; 12-place Packard; back of
speedometer. Unthread rubber boot from odometer
reset switch and pull switch from hole in inner fairing.

Tachometer [108]; 12-place Packard; back of tacho-
meter.

Main to interconnect harness [1], 16-place Molex
(black); anchor in hole of right radio support bracket.

Right handlebar switches [22], 12-place Molex (black);
T-stud on right fairing support brace (middle).

Right front turn signal/auxiliary lamp [31R], 4-place
Multilocks (black); T-stud on right fairing support brace
(outboard side).

Main to interconnect harness [15], 4-place Packard
(black); anchored in hole at front of right fairing
bracket.

Fairing cap switches [105], 12-place Multilock (black);
top of upper fork bracket (right side).

m. Radio [27], 23-place Amp (black); back of radio (right

side).

Front fender tip lamp jumper harness [32], if present;
2-place Multilock (black); below upper fork bracket
(left side).

Ambient temperature sensor [107], if present; 3-place
Multilock (black); anchored in hole on left side of
steering head.

Install anchor on convoluted tubing of headlamp connector
[38] into hole at front of left fairing bracket. See

Figure 8-112

10. Using round hole at side of left fairing bracket, install new

cable strap capturing convoluted tubing of headlamp

connector [38] and conduit of main to interconnect harness
connector [2] and left handlebar switch connector [24].

11. Using oval shaped hole at side of right fairing bracket,

install new cable strap capturing convoluted tubing of radio
connector [27] and conduit of main to interconnect harness
connector [1], main to interconnect harness connector [15]
and right handlebar switch connector [22]. See

Figure 8-113

12. Install outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

13. Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

sm05191

Figure 8-112. Anchor Convoluted Tubing of Headlamp

Connector to Fairing Bracket (Left Side)

sm05209

Figure 8-113. Cable Strap Conduit to Fairing Bracket (Right

Side)

FLTR

Removal

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

Place protective material on top of front fender to protect
paint from scratches or other damage.

8-98 2008 Touring Service: Electrical

Remove outer fairing. See

2.39 UPPER FAIRING AND

WINDSHIELD: FLTR

Carefully cut two cable straps to free wire bundles and
conduit from convoluted tubing of interconnect harness
and allow to hang naturally.

See

Figure 8-114

. Disconnect connectors and remove

from their retaining devices, if present.

Main to interconnect harness [1], 16-place Molex
(black); below radio (right side).

Main to interconnect harness [2], 12-place Molex
(gray); below radio (right side).

Main to interconnect harness [15], 4-place Packard
(black); below radio (right side).

Left handlebar switches [24], 16-place Molex (gray);
T-stud on left side of radio bracket.

Right handlebar switches [22], 12-place Molex (black);
T-stud on left side of radio bracket.

Radio [27], 23-place Amp (black); back of radio (right
side).

Disconnect ambient temperature sensor connector [107],
3-place Multilock, from sensor anchored in hole on left
side of steering head. Feed connector and conduit in
through opening on left side of fairing bracket.

Proceed as follows:

Remove left side of instrument nacelle. See

2.41 INSTRUMENT NACELLE: FLTR

. See

Figure 8-115

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

Pull harness ground socket terminal from spade
contact fastened to top of upper fork bracket (left
side).

Draw branches of interconnect harness (terminating in
odometer reset switch and speedometer, tachometer,
indicator lights, instrument nacelle switches and ambient
temperature sensor connectors) through tunnel of fairing
bracket to front of inner fairing.

Remove left side connectors from spade contacts as fol-
lows:

Cigarette lighter [132].

Left speaker [35].

Fuel gauge [117] and lamp [116].

Air temperature gauge [115] and lamp [114].

10. Remove right side connectors from spade contacts as

follows:

Right speaker [34].

Voltmeter gauge [111] and lamp [110].

Oil pressure gauge [113] and lamp [112].

11. Free conduit of front turn signal lamp connectors [31L]

and [31R], 3-place Multilocks, from flexible clips on sides
of inner fairing.

12. Remove interconnect harness from motorcycle. Remove

radio antenna cable connector [51] at back of radio (left
side), if necessary.

2008 Touring Service: Electrical 8-99

sm05168

Radio [27]

Main to interconnect harness [1]

Main to interconnect harness [2]

Left turn signal [31L]

Right turn signal [31R]

Main to interconnect harness [15]

Right handlebar switches [22]

Headlamp [38]

Left handlebar switches [24]

Figure 8-114. Inner Fairing- Interconnect Harness Connectors (FLTR)

8-100 2008 Touring Service: Electrical

sm02877

Speaker switch [105C/D]

Indicator lights [21]

Speedometer gauge [39]

Tachometer gauge [108]

Clutch cable

Instrument nacelle switches [105A/B]

Figure 8-115. Instrument Nacelle (Bezel Removed)

Installation

NOTE

To avoid chafing wires of interconnect harness, verify that trim
strips are installed on hooks of radio bracket.

Center convoluted tubing of interconnect harness above
and inboard of hooks on radio bracket. To verify proper
orientation, be sure that long length of conduit terminating
in socket terminals of cigarette lighter is on left side of
motorcycle. Install radio antenna cable connector [51] at
back of radio (left side), if removed.

Install left side connectors onto spade contacts as follows:

Cigarette lighter [132]; connect the orange/white wire
socket terminal to the socket spade contact, the black
wire socket terminal to the shell contact.

Left speaker [35].

Fuel gauge [117] and lamp [116].

Air temperature gauge [115] and lamp [114].

Install right side connectors onto spade contacts as fol-
lows:

Right speaker [34].

Voltmeter gauge [111] and lamp [110].

Oil pressure gauge [113] and lamp [112].

Find branch of interconnect harness terminating in odo-
meter reset switch and speedometer, tachometer, indicator
lights and instrument nacelle switch connectors. Feed
connectors and conduit from front of inner fairing through
tunnel of fairing bracket and then out through opening at
top of fairing bracket to instrument nacelle.

Proceed as follows:

Push harness ground socket terminal onto spade
contact fastened to top of upper fork bracket (left
side).

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

Figure 8-115

Install left side of instrument nacelle.

2.41 INSTRU-

MENT NACELLE: FLTR

2008 Touring Service: Electrical 8-101

See

Figure 8-114

. Connect connectors and install onto

their retaining devices, if present.

Main to interconnect harness [1], 16-place Molex
(black); below radio (right side).

Main to interconnect harness [2], 12-place Molex
(gray); below radio (right side).

Main to interconnect harness [15], 4-place Packard
(black); below radio (right side).

Left handlebar switches [24], 16-place Molex (gray);
T-stud on left side of radio bracket.

Right handlebar switches [22], 12-place Molex (black);
T-stud on left side of radio bracket.

Radio [27], 23-place Amp (black); back of radio (right
side).

Orient connectors as shown in

Figure 8-114

. Install two

new cable straps outboard of radio bracket hooks to
secure wire bundles and conduit to convoluted tubing of
interconnect harness. Cut any excess cable strap material.
See

Figure 8-116

Capture conduit of front turn signal lamp connectors [31L]
and [31R], 3-place Multilocks, in flexible clips on sides of
inner fairing.

Install outer fairing. See

2.39 UPPER FAIRING AND

WINDSHIELD: FLTR

10. Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

sm05192

Figure 8-116. Cable Strap Convoluted Tubing and Conduit

8-102 2008 Touring Service: Electrical

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