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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 28

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13. Perform the CABLE LASH INITIALIZATION routine des-

f1548x8x

cribed in this section.

CRUISE CONTROL MODULE

REMOVAL

Cable Clip

1.

Remove the air cleaner and backplate. See Section 4.5

AIR CLEANER, REMOVAL.

Hole

2.

Push the plastic end fitting on the cruise cable to the out-

board side to release from wheel pin. See Figure 8-134.

3.

Remove seat. See Section 2.25 SEAT, REMOVAL.

1WARNING

Figure 8-136. Cruise Cable Routing (Left Side)

Always disconnect the negative battery cable first. If the

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

2.

Slide groove in cruise cable end fitting over cap of wheel

explosion which could result in death or serious injury.

pin. Push on end fitting until it snaps in place. See Figure

8-134.

4.

Unthread bolt and remove battery negative cable (black)

3.

Using slot, slip cruise cable housing into cable guide in

from battery negative (-) terminal.

throttle cable bracket. At bottom of bracket, install new

5.

Unthread bolt and remove battery positive cable (red)

E-clip on sleeve at end of cruise cable housing.

from battery positive (+) terminal.

4.

Feed cruise cable and connector through hole in frame

6.

Loosen T40 TORX screw and move lip of hold-down

crossmember. See Figure 8-136.

clamp off edge of battery. Remove battery from battery

box.

CAUTION

7.

Lift locking latch and remove cruise module connector

Be sure that the ribbon is not twisted. A twisted ribbon

[17], 10-place Packard. See Figure 8-133.

may adversely affect performance or even prevent cruise

8.

Rotate cruise cable connector in a counterclockwise

operation.

direction to detach from cruise module.

5.

With the hole in the ribbon end eyelet and the flat on the

9.

From inside battery box, remove three flange bolts.

cable connector housing facing outboard, fit cable end

Carefully pull cruise module away from side of battery

bead into ribbon end eyelet. See Figure 8-135.

box exercising caution to avoid losing grommets.

6.

Verify that bead, eyelet and ribbon are lined up correctly.

If necessary, remove plastic end fitting from wheel pin

and gently pull on end fitting to remove cable slack.

Reinstall end fitting, if removed.

f2004x8x

Mounting

7.

Insert cruise cable connector into cruise module and

Holes

rotate in a clockwise direction until tabs on connector

fully engage grooves or detentes in cruise module hous-

ing.

8.

Capture cruise cable in cable clip and anchor in hole of

frame crossmember. See Figure 8-136.

9.

Adjust the throttle and idle cables. See CABLE ADJUST-

MENT, in this section.

10. Install backplate and air cleaner assembly. See Section

4.5 AIR CLEANER, INSTALLATION.

11. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

12. Install left side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

Figure 8-137. Battery Box (Right Side View)

2006 Touring: Electrical

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INSTALLATION

CRUISE CONTROL SWITCHES

1.

Install grommets into holes on left side of battery box

with the larger OD on the outboard side. See Figure 8-

FAIRING CAP

137.

2.

Align threaded holes on inboard side of cruise module

See Figure 8-138. For instructions on replacement of the

with holes in grommets and install flange bolts from

CRUISE ON/OFF SWITCH, see Section 8.20 FAIRING

inside battery box.

CAP SWITCHES (FLHTC/U), Section 8.21 INSTRU-

MENT NACELLE SWITCHES (FLTR), or Section 8.22

3.

Alternately tighten flange bolts to 60-96 in-lbs (6.8-10.9

HANDLEBAR SWITCHES (FLHRC).

Nm). Install cruise module connector [17] and engage

locking latch.

Cruise ON/OFF

CAUTION

Switch

Be sure that the ribbon is not twisted. A twisted ribbon

may adversely affect performance or even prevent cruise

operation.

4.

With the hole in the ribbon end eyelet and the

flat on the

cable connector housing facing outboard, fit

cable end

bead into ribbon end eyelet. See Figure 8-135.

5.

Verify that bead, eyelet and ribbon are lined up correctly.

If necessary, remove plastic end fitting from wheel pin

and gently pull on end fitting to remove cable slack.

6.

Insert cruise cable connector into cruise module and

rotate in a clockwise direction until tabs on connector

fully engage grooves or detentes in cruise module hous-

f2031x8x

ing.

Figure 8-138. Fairing Cap (FLHTCU)

7.

Install cruise module connector [17], 10-place Packard.

See Figure 8-133.

8.

Place battery in battery box, terminal side forward.

HANDLEBAR

Rotate the hold-down clamp so that the lip (with rubber

pad) rests on the edge of the battery. Tighten T40 TORX

See Figure 8-139. For instructions on replacement of the

screw to 15-20 ft-lbs (20-27 Nm).

handlebar mounted CRUISE SET/RESUME switch, see

Section

8.22 HANDLEBAR SWITCHES, SWITCH

REPAIR/REPLACEMENT.

1WARNING

Always connect the positive battery cable first. If the

f1368a8x

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion which could result in death or serious injury.

9.

Insert bolt through battery positive cable

(red) into

threaded hole of battery positive (+) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

10. Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

Set/Resume

11. Install seat. See Section 2.25 SEAT, INSTALLATION.

Switch

12. Slide groove in cruise cable end fitting over cap of wheel

pin. Push on end fitting until it snaps in place. See Figure

8-134.

13. Install backplate and air cleaner assembly. See Section

4.5 AIR CLEANER, INSTALLATION.

14. Perform the CABLE LASH INITIALIZATION routine des-

Figure 8-139. Right Handlebar Switch Assembly

cribed in this section.

(FLTR, FLHTCU)

8-108

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ADVANCED AUDIO SYSTEM (FLHX, FLHTC/U, FLTR)

8.32

RADIO (STORAGE BOX)

REMOVAL

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2.

Remove outer fairing. Proceed as follows:

FLHX, FLHT/C/U: See Section 2.30 UPPER FAIRING/

WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/

WINDSHIELD, REMOVAL.

FLTR: See Section

2.31 UPPER FAIRING/WIND-

SHIELD (FLTR), OUTER FAIRING, REMOVAL.

3.

On FLHTCU models, remove the CB module. See CB

MODULE, REMOVAL, steps 3-4, in this section.

f1559x8x

4.

See Figure 8-140. Disconnect the following connectors:

Figure 8-141. Release Radio from Fairing Brackets

FLHX, FLHTC/U, FLTR:

(FLHTC/U)

● Radio connector [27], 23-place Amp.

● Radio antenna cable connector [51].

5.

Using a long shank ball end socket (Snap-on® FABL6E),

remove four socket head screws to release radio (stor-

FLHTCU Only:

age box on FLHT) from left and right radio support

● Radio connector [28], 35-place Amp.

brackets. Use oblong holes in fairing brackets to access

screws. See Figure 8-141.

6.

Pull radio (storage box on FLHT) forward to remove from

f2356x8x

opening in inner fairing.

[50]

[184]

[28]

INSTALLATION

1.

Position radio (storage box on FLHT) between radio sup-

port brackets and push into opening in inner fairing.

2.

Align threaded inserts in sides of radio (storage box on

FLHT) with holes in left and right radio support brackets.

Starting at the rear, install four socket head screws.

Alternately tighten screws to 35-45 in-lbs (4.0-5.1 Nm).

Use oblong holes in fairing brackets to access screws.

3.

See Figure 8-140. Connect the following connectors:

FLHX, FLHTC/U, FLTR:

● Radio connector [27], 23-place Amp.

● Radio antenna cable connector [51].

FLHTCU Only:

● Radio connector [28], 35-place Amp.

4.

On FLHTCU models, install the CB module. See CB

[27]

[51]

MODULE, INSTALLATION, steps 1-3, in this section.

[27] Radio

5.

Install outer fairing. Proceed as follows:

[28] Radio

[51] Radio Antenna Cable

[50] CB Antenna Cable

[184] CB Module

FLHX, FLHT/C/U: See Section 2.30 UPPER FAIRING/

WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/

Figure 8-140.

Radio Connections (FLHTC/U)

WINDSHIELD, INSTALLATION.

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FLTR: See Section

2.31 UPPER FAIRING/WIND-

SHIELD (FLTR), OUTER FAIRING, INSTALLATION.

1.

Console

2.

Pod

6.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

3.

Headset Receptacle

MAXI-FUSE, INSTALLATION.

Cap

2

FRONT FAIRING SPEAKERS

REMOVAL

1.

Remove outer fairing. Proceed as follows:

3

FLHX, FLHTC/U: See Section 2.30 UPPER FAIRING/

WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/

WINDSHIELD, REMOVAL.

f2019x8x

1

FLTR: See Section

2.31 UPPER FAIRING/WIND-

Figure 8-142. Console Pod Assembly

SHIELD (FLTR), OUTER FAIRING, REMOVAL.

2.

Carefully pull the socket terminals from the speaker

spade contacts.

CONSOLE POD ASSEMBLY

3.

Remove three T25 TORX screws to release the speaker

adapter assembly from the inner fairing.

NOTE

4.

Carefully pull speaker from adapter.

The following instructions may also be used for replacement

of the chrome fuel tank console on which the pod is mounted.

INSTALLATION

REMOVAL

1.

With the speaker spade contacts at the top of the

1.

Remove seat. See Section 2.25 SEAT, REMOVAL.

adapter, the top being the side with the widest edge,

snap speaker into adapter using finger pressure.

1

WARNING

2.

If speaker grille is loose, apply 3M-847 adhesive (HD

Part No. 99618-60) to outer edge of adapter ring. Install

To protect against shock and accidental start-up of vehi-

grille on adhesive.

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

3.

With the widest edge of adapter at the top, align holes in

death or serious injury.

speaker adapter assembly with those in inner fairing.

2.

Unthread bolt and remove battery negative cable (black)

4.

Install two long screws to secure top of speaker adapter

from battery negative (-) terminal.

assembly to inner fairing. Capturing fairing support

brace, install short screw in lower outboard hole (posi-

3.

Remove left side saddlebag. See Section 2.26 SAD-

tioning flat washer between adapter and support brace).

DLEBAG, REMOVAL.

The screw hole on the lower inboard side is not used.

4.

Gently pull side cover from frame downtubes (no tools

5.

Using a T25 TORX drive head, tighten the lower speaker

required).

screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten the two

5.

Carefully cut cable strap securing console pod conduit

upper speaker screws to 35-50 in-lbs (4.0-5.7 Nm).

and audio harness to left frame tube at front and rear of

saddlebag rail.

6.

Install the socket terminals onto the speaker spade con-

tacts. Different size spade contacts prevent improper

6.

Open fuel door on console. Remove two Allen head

assembly.

screws inboard of rubber bumpers. These screws secure

console to clip nuts on the canopy bracket.

7.

Install outer fairing. Proceed as follows:

7.

Remove Allen head screw to detach flange at rear of

FLHX, FLHTC/U: See Section 2.30 UPPER FAIRING/

console from clip nut on fuel tank weldment.

WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/

WINDSHIELD, INSTALLATION.

8.

Lay a clean shop towel on forward part of the rear

fender. Remove filler cap from neck of fuel tank. Remove

FLTR: See Section

2.31 UPPER FAIRING/WIND-

console and lay upside down on shop towel. Reinstall

SHIELD (FLTR), OUTER FAIRING, INSTALLATION.

filler cap.

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2006 Touring: Electrical

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9.

Bend back flexible clamp to release pod cable conduit

from bottom of console.

f2007x9x

10. Release console pod connector [53], 12-place Deutsch,

from attachment clip anchored in hole of frame cross-

member (at rear of battery box). See Figure 8-143. Dis-

1

2

connect pin and socket halves.

11. Remove three Phillips screws to release pod from con-

sole.

INSTALLATION

1.

Feed pin housing and conduit through top of console

3

seating pod in recess. Install three Phillips screws

screws to secure pod to console. Alternately tighten

4

screws to 6-11 in-lbs (0.7-1.2 Nm). Capture conduit in

flexible clamp at bottom of console.

1WARNING

1.

Fuel Vapor Vent Tube (To Vapor Valve)

Exercise caution to avoid pinching or kinking the fuel

2.

Fuel Overflow Hose

overflow hose when console is installed. A blocked hose

3.

Fuel Tank Harness

can cause excess gasoline to remain above the filler

(To Fuel Pump/Fuel Level Sender)

neck insert, while fuel expansion can cause an overfilled

4.

Console Pod Conduit

tank to overflow through the filler cap vent. Gasoline is

extremely flammable and highly explosive. Inadequate

Figure 8-144. Console Pod Cable/Hose Routing

safety precautions could result in death or serious

(FLHTCU)

injury.

2.

Remove filler cap. Place console over filler neck onto

canopy. Route cables from beneath console as shown in

3.

Install Allen head screw to fasten rear flange of console

Figure 8-144. Be sure that hoses and wires are not

to clip nut on fuel tank weldment. Tighten screw to 25-30

pinched by the console during installation. Reinstall filler

in-lbs (2.8-3.4 Nm).

cap.

4.

Open fuel door on console. Install two Allen head screws

to secure front of console to clip nuts on canopy bracket.

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Cable Strap

Console Pod

Connector [53]

5.

Install new cable straps to secure console pod conduit

and audio harness to left frame tube at front and rear of

saddlebag rail. Cut any excess cable strap material. See

Figure 8-143.

6.

Connect console pod connector [53], 12-place Deutsch.

Install connector onto attachment clip anchored in hole

of frame crossmember (at rear of battery box).

7.

Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

8.

Install seat. See Section 2.25 SEAT, INSTALLATION.

9.

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

10.

Install left side saddlebag. See Section 2.26 SADDLE-

f2192x8x

BAG, INSTALLATION.

Figure 8-143. Disconnect Console Pod Connector

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FRONT HEADSET RECEPTACLE

Table 8-18. Front Headset Receptacle

Chamber

Wire Color

REMOVAL

Number

Blue/Yellow

6

1.

Remove console pod. See CONSOLE POD ASSEM-

BLY, REMOVAL, in this section.

Yellow/Black

7

2.

Remove terminals 6 through 12 from pin housing of 12-

Yellow/White

8

place Deutsch connector.

Yellow/Red

9

NOTE

Black

10

For instructions on properly removing wire terminals, see

Red

11

APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

Black (Thick Insulation)

12

REMOVING/INSTALLING PINS.

3.

Raise headset receptacle cap. Place pin punch in either

NOTE

notch of lock ring and rotate in a counterclockwise direc-

For instructions on properly installing wire terminals, see

tion until loose. See Figure 8-145.

APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

4.

Remove lock ring and cap from headset receptacle.

REMOVING/INSTALLING PINS.

5.

Remove headset receptacle from pod.

6.

Install console pod. See CONSOLE POD ASSEMBLY,

INSTALLATION, in this section.

INSTALLATION

7.

Test operation of headset receptacle.

1.

From inside pod, insert threaded end of headset recep-

tacle through side hole.

REAR HEADSET RECEPTACLE

2.

Place receptacle cap over end of headset receptacle so

that it seats in recess of pod.

See Section 8.37 AUDIO HARNESS (FLHTCU).

3.

Open cap, and with the notches on the outboard side,

thread lock ring onto headset receptacle.

4.

Place pin punch in either notch of lock ring and rotate in

REAR PASSENGER SWITCHES

a clockwise direction until tight.

5.

Install terminals 6 through 12 into pin housing of 12-

place Deutsch connector.

REMOVAL

NOTE

Right and left side replacement passenger switch assem-

blies are interchangeable.

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

Lock Ring

2.

Open Tour-Pak.

3.

Remove four T10 TORX screws and pull speaker grille

from speaker box.

4.

Remove speaker from speaker box and carefully pull

socket terminals from speaker spade contacts.

5.

Remove trim ring and gently pull on wire harness to

draw rear speaker/passenger controls connector,

6-

place Deutsch, out of speaker box.

f2020x8x

6.

Disconnect pin and socket halves of Deutsch connector.

Figure 8-145. Remove Lock Ring from Receptacle

7.

Draw socket half of Deutsch connector back into

Using Pin Punch

speaker box and pull out through speaker hole.

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NOTE

For instructions on properly installing wire terminals, see

APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

REMOVING/INSTALLING SOCKETS.

Switch

3.

With the Pink/White wire at the bottom, place switch in

Bracket

cavity of switch housing. Bottom of the assembly is

determined by location of rib on switch housing. See Fig-

ure 8-147.

4.

Note lettering for proper orientation and gently push key-

TORX

cap onto switch shaft. When orienting keycap, remember

Screw

that bottom of assembly is determined by location of

switch housing rib.

5.

Feed Deutsch socket connector, speaker terminals and

conduit through switch housing hole on outboard side of

speaker box until switch housing backplate contacts

speaker box. Pull harness out through speaker hole.

f1492b8x

NOTE

To align bracket and switch housing holes, slot in bracket

Figure 8-146. Remove Passenger Switch Assembly

must face toward the front on right side assembly and toward

(Right Side Speaker Box Shown)

the rear on left side. See Figure 8-148. Switch also must be

square in cavity of switch housing or bracket will not fit.

8.

Remove two T25 TORX screws to release switch bracket

6.

Reaching into speaker box, align holes in bracket with

from inside of speaker box. Remove bracket using slot to

holes in switch housing. Install two T25 TORX screws.

free switch wires. See Figure 8-146.

See Figure 8-149.

9.

Pull switch housing assembly, wire harness conduit,

7.

Feed Deutsch socket through speaker hole into speaker

speaker terminals and Deutsch socket from speaker box

box and pull out through harness hole on inboard side.

using switch housing hole on outboard side.

8.

Mate pin and socket halves of Deutsch connector. Feed

10. Carefully pull keycap from switch shaft. Remove switch

connector back up into speaker box pressing trim ring

from switch housing.

into hole.

11. Remove terminals 1 through 4 from socket housing.

9.

Install socket terminals onto speaker spade contacts. On

right side of vehicle, install socket terminal of the solid

NOTE

Green wire onto contact next to the red dot. On left side,

For instructions on properly removing wire terminals, see

install socket terminal of the solid Brown wire onto con-

APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,

tact next to the red dot.

REMOVING/INSTALLING SOCKETS.

10. Align holes in speaker grille with those in speaker and

12. Pulling one wire at a time, remove four wires from con-

slide four TORX screws through grille and speaker

duit.

holes.

11. With spade contacts at bottom rear corner, position

speaker/grille assembly against speaker box. Install four

INSTALLATION

T10 TORX screws and alternately tighten in a crosswise

1.

Pushing one wire at a time, feed four wires of new switch

pattern.

through conduit.

12. Close Tour-Pak.

2.

Install terminals 1 through 4 into socket housing.

13. Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

Table 8-19. Rear Passenger Switches

14. Test switch for proper operation.

Chamber

Wire Color

Number

REAR SPEAKERS

Pink/White

1

Gray/White

2

REMOVAL

Violet/Black

3

* Orange/Black

4

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

* Mates to O/BK on [41A], BN/W on [42A].

2006 Touring: Electrical

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f1494b8x

f1491x8x

1

Front on right side,

rear on left side.

3

Figure 8-148. Properly Orient Slot in Switch Bracket

2

DISASSEMBLED

f1495x8x

ASSEMBLED

Slot

Forward

4

6

Rib

5

Bottom

1.

Passenger Switch

4.

Pink/White Wire

2.

Switch Housing

5.

Rib

3.

Cavity

6.

Keycap

Figure 8-147. Install Switch in Housing

2.

Open Tour-Pak.

3.

Remove four T10 TORX screws from speaker grille.

Remove speaker grille from speaker box.

f1492x8x

4.

Remove speaker from speaker box. Carefully pull two

Figure 8-149. Install Passenger Switch Assembly

socket terminals from speaker spade contacts.

(Right Side Speaker Box Shown)

INSTALLATION

2.

With spade contacts at bottom, install speaker in

speaker box.

1.

Install two socket terminals onto speaker spade con-

tacts. Different size spade contacts prevent improper

3.

Align holes in speaker with those in speaker box. Align

assembly.

holes in grille with those in speaker.

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WIRE TROUGH

8.33

REMOVAL

9306

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

REMOVAL, FLHX, FLHT or FLHR/S. For fuel injected

models, see Section

9.4 FUEL TANK

(FUEL

INJECTED), COMPLETE REMOVAL, FLHXI, FLHT/C/

U/I, FLTRI or FLHR/C/S/I.

2.

Unthread bolt and remove battery positive cable (red)

from battery positive

(+) terminal.

(Battery negative

cable already removed under FUEL TANK, COMPLETE

REMOVAL.)

3.

Loosen T40 TORX screw and move lip of hold-down

clamp off edge of battery. Remove battery from battery

box.

Figure 8-150. Release Catches From Cover

4.

Starting at the front of the wire trough, and working

rearward from side to side, release catches to remove

9294

cover. For most catches, carefully insert blade of flat tip

screwdriver into slot only as far as necessary to release

catch. See Figure 8-150.

5.

Using a paint pen, draw a line on the conduit and/or wire

bundle on both sides of each cable strap. See Figure 8-

151.

NOTE

If multiple branches of the harness are bound by a single

cable strap, such as the breakouts leading to the induction

module on fuel injected models, be sure to mark all branches

with the paint pen.

6.

Starting at the front of the wire trough, cut the first cable

strap as close to the eyelet as possible. Be sure to cut off

Figure 8-151. Mark Location of Cable Straps

the tail of the cable strap and not the eyelet. The cable

strap can be reused for use in step 7 if only the tail is

9298

removed, but it must be replaced with a new cable strap

if the eyelet is cut off. See Figure 8-152.

7.

Remove the tail remnant from the eyelet of the cable

REUSABLE

strap, if present. Remove the cable strap from the slots

(tail removed)

in the wire trough and install it back on the harness just

outside the painted lines. Be sure to capture each wire

of the harness, but not the wire trough. Repeat steps 6-7

for all remaining cable straps.

NOTE

If multiple branches of the harness are bound by a single

cable strap, such as the breakouts leading to the induction

module on fuel injected models, install new cable strap just

NOT REUSABLE

(eyelet removed)

outside the painted lines before cutting original cable strap

through wire trough. This will further ensure that stackup and

breakout lengths remain the same.

Figure 8-152. Cut Cable Straps

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8.

Gently pull index pins on rear legs of wire trough from

holes in frame backbone. For best results, work both

pins loose at the same time.

9.

Slide wire trough forward to release slot at bottom from

T-stud a center of frame backbone.

10. Raise wire harness and carefully remove wire trough

from left side of motorcycle.

INSTALLATION

1.

Thread cable straps through slots of new wire trough as

f2399x8x

shown in Figure 8-153. Properly installed, both ends of

the cable strap will be pointing upward. Install all cable

Figure 8-153. Install New Cable Straps in Wire Trough

straps in this fashion.

NOTE

Depending upon model, there are a minumum of 17 cable

straps

(carbureted FLHR/S) and a maximum of 20 (fuel

injected FLHTCU). See Figure 8-155 in conjunction with

Table 8-20 below. For example, if installing the wire trough on

a fuel injected FLHTCU, start cable straps in all slots except

18. If installing the wire trough on a carbureted FLHR/S, start

cable straps in all slots except 2, 7, 9 and 19.

Table 8-20. Wire Trough Cable Straps

Cable

Captures

Models

Strap

Conduit/Wire Bundle

1

Main Harness

All

9304

2

Audio Harness

FLHTCU

Figure 8-154. Rear Leg Index Pins

Ignition Coil

All

3

Fuel Gauge

FLHR/C/S

Main Harness

All

2.

Raise wire harness, and from left side of motorcycle,

4

carefully slide wire trough into position on frame

Audio Harness

FLHTCU

backbone.

5

Main Harness

All

3.

Slide wire trough rearward to engage slot at bottom on T-

Main Harness

All

6

stud at center of frame backbone.

Audio Harness

FLHTCU

4.

Gently push index pins on rear legs of wire trough into

7

Front Fuel Injector

Fuel Injected

holes in frame backbone. See Figure 8-154.

TP Sensor, MAP Sensor,

Fuel Injected

IAC and Rear Fuel Injector

5.

Lay harness in wire trough so that the painted lines are

8

adjacent to the cable straps. Start tail end of each cable

MAP Sensor

Carbureted

strap into eyelet, but do not tighten.

TP Sensor, MAP Sensor,

9

Fuel Injected

IAC and Rear Fuel Injector

6.

Adjust harness as necessary, so that the painted lines

are aligned with the cable straps threaded through the

Horn

All

10

wire trough.

ET Sensor

Fuel Injected

7.

Tighten the cable straps and cut any excess cable strap

Main Harness

All

11-17

material.

Audio Harness

FLHTCU

8.

Carefully cut and remove all cable straps not threaded

18

Instrument Console

FLHR/C/S

through the wire trough, that is, those installed just

19

Fuel Tank Harness

FLHX, FLHT/C/U, FLTR

outside the painted lines in step 7 under REMOVAL.

20-21

Main Harness

All

2006 Touring: Electrical

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3

1

2

6

10

4

11

5

12

8

14

9

7

13

16

15

18

19

17

20

NOTE

Refer to Table 8-20 for reference

21

number identification.

f2429x8x

Figure 8-155. Wire Trough Cable Strap Locations (FLHTCU)

9.

Place cover over wire trough. Starting at the front and

11. Insert bolt through battery positive cable

(red) into

working rearward from side to side, engage catches to

threaded hole of battery positive (+) terminal. Tighten

latch cover. Verify that all latches are fully engaged.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

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

12. Insert bolt through battery negative cable (black) into

Rotate the hold-down clamp so that the lip (with rubber

threaded hole of battery negative (-) terminal. Tighten

pad) rests on the edge of the battery. Tighten T40 TORX

bolt to 60-96 in-lbs (6.8-10.9 Nm).

screw to 15-20 ft-lbs (20-27 Nm).

13. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

1WARNING

COMPLETE REMOVAL), FLHX, FLHT or FLHR/S. For

fuel injected models, see Section 9.4 FUEL TANK (FUEL

Always connect the positive battery cable first. If the

INJECTED), INSTALLATION

(AFTER COMPLETE

positive cable should contact ground with the negative

REMOVAL), FLHXI, FLHT/C/U/I, FLTRI or FLHR/C/S/I.

cable installed, the resulting sparks may cause a battery

explosion which could result in death or serious injury.

8-118

2006 Touring: Electrical

HOME

MAIN HARNESS

8.34

NOTE

REMOVAL

Depending upon model, continue procedure at REMOVAL-

FLHR/C/S

(PART II), REMOVAL- FLTR

(PART II), or

REMOVAL- ALL MODELS (PART I)

REMOVAL- FLHX, FLHT/C/U (PART II).

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

REMOVAL- FLHR/C/S (PART II)

REMOVAL, FLHX, FLHT or FLHR/S. For fuel injected

models, see Section

9.4 FUEL TANK

(FUEL

1.

Remove the headlamp assembly. See Section 8.11

INJECTED), COMPLETE REMOVAL, FLHXI, FLHT/C/

HEADLAMP (FLHR/C/S, FLHX, FLHT/C/U), HEAD-

U/I, FLTRI or FLHR/C/S/I.

LAMP ASSEMBLY, REMOVAL.

2.

Unthread bolt and remove battery positive cable (red)

2.

See Figure

8-156. Reaching inside the headlamp

from battery positive

(+) terminal.

(Battery negative

nacelle, disconnect main harness as follows:

cable already removed under FUEL TANK, COMPLETE

● Front fender tip lamp jumper harness connector

REMOVAL.)

[32], 2-place Multilock (black); used on FLHR only.

3.

Loosen T40 TORX screw and move lip of hold-down

● Auxiliary lamps connector [73], 2-place Multilock

clamp off edge of battery. Remove battery from battery

(white); used on FLHR/C only.

box.

● Auxiliary lamps switch connector

[109],

4-place

4.

Remove left side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

Amp; used on FLHR/C only.

5.

Gently pull left side cover from frame downtubes (no

● Accessory switch connector [67], 4-place Amp.

tools required).

● Right handlebar switch controls connector [22], 6-

6.

Repeat steps 4-5 to remove right side saddlebag and

place Deutsch (black); T-stud on fork stem nut lock-

side cover.

plate (left side).

f2212x8x

[159]

[31]

[24]

[22]

[158]

[109]

[67]

[22] Right Handlebar Switches

[24] Left Handlebar Switches

[31] Front Turn Signals

[32] Front Fender Tip Lamp (Used on FLHR Only)

[32]

[38] Headlamp

[67] Accessory Switch

[73] Auxiliary Lamps (Used on FLHR/C Only)

[109] Auxiliary Lamps Switch (Used on FLHR/C Only)

[38]

[158] Cruise On/Off Switch (Used on FLHRC Only)

[73]

[159] Cruise Set/Resume Switch (Used on FLHRC Only)

Figure 8-156. Headlamp Nacelle - Main Harness Connectors (FLHR/C/S)

2006 Touring: Electrical

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f2095x8x

4

5

1

5

3

6

1.

Ignition/Light Key Switch Connector [33]

2

5

2.

Indicator Lights Connector [21]

3.

Speedometer Connector [39]

5.

Flexible Clip (3)

4.

Odometer Reset Switch

6.

Plastic Clip

Figure 8-157. Instrument Console Assembly - Main Harness Connectors (FLHR/C)

● Cruise set/resume switch connector [159], 2-place

7.

Bend back flexible clamps on inboard side of instrument

Deutsch (black); used on FLHRC only.

console as necessary to release main harness conduit.

Set instrument console aside.

● Front turn signal lamps connector [31], 6-place Mul-

tilock; anchored in hole of fork stem nut lock plate

NOTE

(left side).

Continue procedure at REMOVAL- ALL MODELS (PART III).

● Left handlebar switch controls connector [24], 6-

place Deutsch (gray); T-stud on fork stem nut lock-

plate (left side).

REMOVAL- FLHX, FLHT/C/U (PART II)

● Cruise on/off switch connector [158], 2-place Deut-

sch (gray); used on FLHRC only.

1.

Remove the outer fairing and windshield. See Section

2.30 UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/

3.

Carefully pull main harness rearward under right side of

U), OUTER FAIRING/WINDSHIELD, REMOVAL.

headlamp nacelle allowing conduit and connectors to

2.

Cut cable strap to release convoluted tubing of intercon-

hang over top of engine guard.

nect harness and conduit of main to interconnect har-

ness connectors [1], [2], [15] and [156] from right fairing

4.

Remove screw and P-clamp to release main harness

from right side of steering head.

bracket.

3.

See Figure 8-158. Disconnect main harness from inter-

5.

See Figure 8-157. Moving to inboard side of instrument

connect harness as follows:

console, disconnect main harness as follows:

● Main to interconnect harness connector [1], 12-

● Ignition/Light Key Switch connector [33],

3-place

place Deutsch (black); T-stud on right radio support

Packard.

bracket.

● Indicator lights connector [21], 8-place Deutsch.

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); T-stud on right fairing support

● Speedometer connector [39], 12-place Packard.

brace (middle).

● Main to interconnect harness connector [15], 4-

6.

Unthread rubber boot from odometer reset switch and

place Packard (black); anchored in hole at front of

pull switch from hole in instrument console.

right fairing bracket.

8-120

2006 Touring: Electrical

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[1]

f2356x8x

[156]

[2]

[15]

[51]

[1] Main to Interconnect Harness

[2] Main to Interconnect Harness

[33]

[15] Main to Interconnect Harness

[33] Ignition Switch

[51] Radio Antenna Cable

[156] Main to Interconnect Harness

Figure 8-158. Inner Fairing - Main Harness Connectors (FLHX,

FLHTC/U)

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); T-stud on right fairing support

brace (inboard side).

4.

See Figure 8-158. Disconnect radio antenna cable. Pro-

ceed as follows:

● Radio antenna cable connector [51]; back of radio

(left side).

5.

See Figure 8-158. Disconnect ignition/light key switch

connector

[33],

3-place Packard, at front of ignition

switch housing. Proceed as follows:

a. 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. See Figure 8-

f1559x8x

159.

b. Carefully cut anchored cable strap to release main

Figure 8-159. Release Radio from Fairing Brackets

harness conduit from bottom right corner of radio.

(FLHTC/U)

2006 Touring: Electrical

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c. Obtain the IGNITION SWITCH CONNECTOR

REMOVER (HD-45961).

f2375x8x

[91]

d. Lift radio slightly and gently insert end of tool into

slot in ignition switch housing until it stops.

e. Grasping main harness conduit and tool, pull both

at the same time to release socket housing from

ignition switch housing.

6.

Remove screw, main harness ground ring terminal and

P-clamp to release main harness (and audio harness on

FLHTCU models) from right side of steering head.

7.

Carefully pull main harness rearward under right side of

fairing cap allowing conduit and connectors to hang over

top of engine guard.

8.

For FLHTCU models only, see Section 8.37 AUDIO

HARNESS (FLHTCU), REMOVAL, steps 6 and 8.

NOTE

Continue procedure at REMOVAL- ALL MODELS (PART III).

[10] ICM

[10]

[91] Data Link

REMOVAL- FLTR (PART II)

Figure 8-160. Electrical Bracket (Under Right Side Cover)

1.

Remove the inner fairing. See Section 2.31 UPPER

FAIRING/WINDSHIELD

(FLTR), INNER FAIRING,

REMOVAL, steps 1-20.

f1847x8x

2.

Remove screw, two main harness ground ring terminals

and P-clamp to release main harness bundle from right

side of steering head.

NOTE

Continue procedure at REMOVAL- ALL MODELS (PART III).

[65]

REMOVAL- ALL MODELS (PART III)

1.

If cruise equipped, locate the cruise control roll-off

switch plumbed into the idle cable on right side of the

steering head. Push rubber boot on switch forward and

remove insulators from switch spade terminals.

2.

Depending upon whether the motorcycle is carbureted

or fuel injected, proceed as follows:

Carbureted:

a. Remove ignition coil connector [83] and MAP sen-

sor connector [80].

[65] VSS

[142]

[142] P&A Security Siren

b. Remove ICM connector [10]. See Figure 8-160.

c. Gently pull on data link connector [91] to disengage

Figure 8-161. Electrical Bracket (Inboard Side)

from arms on electrical bracket.

d. Remove two flange nuts to release electrical

bracket from studs on side of battery box.

e. On inboard side of electrical bracket, disconnect

CAUTION

VSS connector [65]. See Figure 8-161. Release

connector and conduit from electrical bracket.

Damage to wires can result in electrical problems. Be

sure that rubber boot is present on threaded end of bat-

f.

Release security siren connector [142] and conduit

tery box TORX screw. Replace rubber boot if absent or

from electrical bracket.

damaged. See upper frame of Figure 8-162.

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2006 Touring: Electrical

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g. Pull back boot and disconnect ET sensor connector

8321

[90] at back of front cylinder. Cut cable strap to

release conduit from horn bracket.

h. Returning to right side of motorcycle, disconnect

ECM connector [78].

i.

Gently pull on data link connector [91] to disengage

from arms on electrical bracket.

j.

Locate painted white dot on inboard side of fuse

block [119]. Pressing on dot, gently tug on conduit

Rubber

to release tabs on fuse block from slots in bracket.

Boot

k. Remove two flange nuts to release electrical

bracket from studs on side of battery box.

l.

On inboard side of electrical bracket, disconnect

VSS connector [65]. See Figure 8-161. Release

connector and conduit from electrical bracket.

m. Release security siren connector [142] and conduit

from electrical bracket.

CAUTION

Damage to wires can result in electrical problems. Be

sure that rubber boot is present on threaded end of bat-

tery box TORX screw. Replace rubber boot if absent or

damaged. See upper frame of Figure 8-162.

n. Note that a section of the main harness conduit

runs forward of the front battery box TORX screw.

Pull conduit to the rear of the screw, and then feed

8319

f2363x9x

Figure 8-162. Remove Main Harness From Vehicle

[84A]

[87A]

Front

g. Note that a section of the main harness conduit

runs forward of the front battery box TORX screw.

Pull conduit to the rear of the screw, and then feed

ICM, data link, VSS, and security siren conduit and

connectors through opening into battery box. See

upper and lower frames of Figure 8-162.

Fuel Injected:

a. Remove air cleaner and backplate. See Section 4.5

AIR CLEANER, REMOVAL.

b. Remove front fuel injector connector [84].

[89A]

c. Remove IAC connector [87] and MAP sensor con-

[85A]

[80A]

[88A]

nector [80]. See Figure 8-163.

d. Remove TP sensor connector [88] and IAT sensor

[80A] MAP Sensor

[87A] IAC

connector [89].

[84A] Front Fuel Injector

[88A] TP Sensor

e. Remove rear fuel injector connector [85].

[85A] Rear Fuel Injector

[89A] IAT Sensor

f.

Moving to left side of motorcycle, remove ignition

coil connector [83] from left side of ignition coil.

Figure 8-163. Induction Module Assembly (Top View)

2006 Touring: Electrical

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7

f2427x8x

1

6

5

4

3

2

1.

Main Harness Ground Ring Terminals (2)

2.

B+ Connector [160]

5.

Accessory Connector [4]

3.

Battery Negative Cable

6.

Chassis Ground Cable

4.

Battery Positive Cable

7.

Main Harness Ground Ring Terminal

Figure 8-164. Upper Frame Cross Member (Under Seat) - Main Harness Connectors (FLHX, FLHTC/U)

ECM, fuse block, data link, VSS, and security siren

6.

Moving to right side of motorcycle, pull back boot at top

conduit and connectors through opening into bat-

of starter housing and remove flange nut and main

tery box. See upper and lower frames of Figure 8-

power cable ring terminal from post. Release cable from

162.

clip anchored to T-stud at front of battery tray. Draw main

power cable to left side of motorcycle.

3.

Moving to left side of motorcycle, remove acorn nut to

release horn bracket from rubber mount stud. Pull elbow

7.

Carefully cut anchored cable strap to release fuse block

terminals from spade contacts and release conduit from

conduit from fuse block bracket. Pull fuse block from

J-clamp.

tabs on bracket.

4.

Remove flange nut (10 mm) from left side ground stud

on upper frame crossmember. Remove two main har-

8.

Remove the fuse block cover. Raise lipped side slightly

ness ground ring terminals (with orange tape). Repeat

to disengage slots from tabs on fuse block.

step to remove main harness ground ring terminal (with-

9.

If cruise equipped, lift the locking latch and remove

out orange tape) and chassis ground ring terminal from

cruise module connector [17]. From inside battery box,

right side ground stud.See Figure 8-164.

remove three flange bolts. Carefully pull cruise module

5.

Depress latches on maxi-fuse holder and then slide

away from side of battery box exercising caution to avoid

cover rearward to disengage tongue from groove in fuse

losing grommets.

block cover.

8-124

2006 Touring: Electrical

HOME

f2317x2x

Battery

Box

See Figure 8-164.

6

1

5

4

3

2

1.

Cable Strap: Captures Main Harness Conduit and Lower Frame Tube

2.

Cable Clip: Captures Main Harness Conduit and Rear Brake Line

3.

Cable Clip: Captures Main Harness Conduit and Rear Brake Line

4.

Cable Strap: Captures Rear Brake Light Switch Wires, Main Harness Conduit and Lower Frame Tube

5.

Cable Strap: Captures Main Harness Conduit and Frame Downtube

6.

Anchored Cable Strap: Captures Main Harness Conduit, Neutral Switch Conduit and VSS Cable

Figure 8-165. Cable Strap Locations (Right Side View)

a. Loosen locknuts on studs of lower frame crossmem-

24. Remove starter solenoid connector [128] at top of starter

ber.

housing.

b. Lift voltage regulator and release voltage regulator

25. Remove two elbow connectors from neutral switch

connector conduit and CKP sensor connector con-

posts.

voluted tubing from P-clip at front of right side leg of

voltage regulator.

26. Pull two socket terminals from spade contacts on rear

c. Pull away locking latch and remove socket of volt-

brake light switch. Cut cable strap to free rear brake light

age regulator connector.

switch wires from lower frame tube.

21.

Locate oil pressure switch/sender at front right side of

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

crankcase. On FLHR/C/S models, pull elbow from post

to release main harness conduit from frame downtube.

of oil pressure switch. On FLHX, FLHT/C/U and FLTR

28. Cut anchored cable strap in hole of frame downtube

models, remove Delphi connector from oil pressure

(inboard of rear swingarm bracket) to release VSS cable,

sender.

main harness and neutral switch conduit.

22.

Cut cable strap to free main harness conduit (leading to

oil pressure sender and CKP sensor connectors) from

29. Draw neutral switch wires out from under starter hous-

inboard side of rear brake pedal weldment. See Figure

ing. For best results, reach in under right side of battery

8-165.

box.

23.

Open two cable clips on lower frame tube T-studs. Free

30. Carefully pull voltage regulator, CKP sensor, oil pressure

main harness conduit from cable clips.

switch/sender, rear brake light switch, starter solenoid,

NOTE

and neutral switch conduit and connectors rearward and

then feed up through opening at front of battery tray into

For best results, insert blade of small screwdriver into gap at

battery box. See lower frame of Figure 8-162.

side of clip and gently rotate end of screwdriver to pop open.

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2006 Touring: Electrical

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