Content      ..     27      28      29      30     ..

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 29

HOME

13.

Route main power cable on maxi-fuse holder through

1

9425

opening above front of fuse block bracket and then for-

ward passing under frame crossmember toward right

side of motorcycle. Pull back boot at top of starter hous-

ing and install ring terminal on post. Install flange nut

and tighten to 70-90 in-lbs (7.9-10.2 Nm). Capture cable

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

14.

Returning to left side of motorcycle, slide maxi-fuse

cover forward to engage tongue in groove of fuse block

cover and then insert maxi-fuse holder into cover until

latches engage.

15.

Install new anchored cable strap in lower hole on left

side of frame crossmember (in front of battery box).

Tighten cable strap to capture conduit of both accessory

connector [4] and B+ connector [160] approximately one

inch from connector housings. See Figure 8-164.

2

16.

Hold vapor valve in position on right side of mounting

bracket. From left side of bracket, insert end of small

Figure 8-166. Capture Radio Antenna Cable (FLTR)

cable strap through hole in arm and then around body of

vapor valve. Mate ends of cable strap and pull tight

engaging strap in slot of arm. Cut any excess cable strap

9364

material.

17.

Depending upon model, proceed as follows:

FLHR/C/S: Move to step 18.

FLHX:

a. Feed radio antenna cable and rear facia lamp wires

rearward following inboard side of upper frame tube.

b. Mate pin and socket housings of rear facia lamp

connector [12], 3-place Multilock.

c. 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).

d. Using slotted hole, install new cable strap to secure

rear facia lamp wires and radio antenna cable to

rear fender support. See Figure 8-167.

e. At bottom of radio antenna bracket, rotate knurled

ring to mate pin and socket halves of radio antenna

cable connector [51].

f.

Install chrome frame tube cover on frame tube.

Figure 8-167. Capture Radio Antenna Cable (FLHX)

Install Phillips screw and tighten to

25-40 in-lbs

(2.8-4.5 Nm). Install bolt (with flat washer) to fasten

saddlebag front mounting bracket and passenger

seat strap to chrome frame tube cover.

11. If cruise equipped, install grommets into holes on left

side of battery box with the larger OD on the outboard

FLHTC/U:

side. Align threaded holes on inboard side of cruise

module with holes in grommets and install flange bolts

a. Feed Tour-Pak lights and radio antenna cable con-

nectors and conduit through hole at front of Tour-

from inside battery box. Alternately tighten flange bolts

to 60-96 in-lbs (6.8-10.9 Nm). Install cruise module con-

Pak. Capture cable and conduit in grommet. Install

nector [17] and engage locking latch.

grommet in hole with the larger OD facing inside.

b. Connect Tour-Pak lights connector

[12],

3-place

12. Slide cover over fuse block until slots fully engage tabs

on block. Slide fuse block into position on mounting

Multilock.

bracket. Tabs on bracket fit into slots on each side of

c. Rotate knurled ring in a clockwise direction to mate

fuse block cover. Install new anchored cable strap in

pin and socket halves of radio antenna cable con-

hole at rear of fuse block bracket. Tighten cable strap to

nector [51]. Capture cable in two adhesive clips at

capture fuse block conduit.

bottom of Tour-Pak.

8-128

2006 Touring: Electrical

HOME

b. Install ECM connector [78].

Frame

f2425x8x

c. Verify that protective plug is installed in data link

Backbone

connector [91]. With the plug side down and in con-

tact with tab, position connector between arms on

electrical bracket.

Saddlebag

Guard

1

34.

Depending upon whether the motorcycle is carbureted

or fuel injected, proceed as follows:

Carbureted:

2

a. Install ignition coil connector [83] onto left side of

ignition coil.

b. Install MAP sensor connector [80].

1

2

Captures main harness, audio harness (FLHTCU only),

Fuel Injected:

console pod conduit (FLHTCU only) and upper frame

tube.

a. Install rear fuel injector connector [85]. See Figure

8-163.

Figure 8-168. Capture Main Harness Conduit

b. Install IAT sensor connector [89] and TP sensor

connector [88].

c. Install MAP sensor connector [80] and IAC connec-

INSTALLATION- FLHR/C/S (PART II)

tor [87].

1.

Carefully feed main harness conduit and connectors for-

d. Install front fuel injector connector [84]. See Figure

ward under right side of instrument nacelle (keeping out-

8-163.

board of the front brake line).

e. Feed ignition coil and ET sensor connectors to left

2.

Install P-clamp on main harness bundle. Install screw to

side of vehicle, routing the first in front of the top

fasten P-clamp to right side of steering head.

engine stabilizer link, the latter to the rear.

3.

Moving to front of motorcycle, reach inside headlamp

f.

Install ignition coil connector [83] onto left side of

nacelle and install screw to fasten harness ground ring

ignition coil.

terminal and brake line P-clamp to front of upper fork

g. Install ET sensor connector [90] at back of front cyl-

bracket.

inder. Pull boot over sensor to keep out dirt and

4.

See Figure 8-156. Connect main harness as follows:

debris. Install new cable strap to secure connector

● Front fender tip lamp connector [32], 2-place Mul-

conduit to horn bracket.

tilock (black); used on FLHR only.

h. Install backplate and air cleaner. See Section 4.5

AIR CLEANER, INSTALLATION.

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

(white); used on FLHR/C only.

35.

If cruise equipped, install cruise roll-off switch as follows:

● Auxiliary lamps switch connector

[109],

4-place

a. Separate the cruise roll-off switch wires up to the

Amp; used on FLHR/C only.

point where they enter the main harness conduit.

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

b. Orient the idle cable so that the switch spade termi-

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

nals are at the top.

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

c. Slide the insulators onto the switch spade terminals

plate (left side).

(polarity is not a factor). For maximum insertion, be

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

sure that the external step on the insulators face

Deutsch (black); used on FLHRC only.

each other.

●

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

d. Fit the rubber boot over the cruise control roll-off

tilock; anchored in hole of fork stem nut lock plate

switch. An oval cut in the boot accommodates the

(left side).

switch spade terminal connections.

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

36.

Install two new cable straps to secure main harness to

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

left upper frame tube. Cut any excess cable strap mate-

plate (left side).

rial. See Figure 8-168.

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

sch (gray); used on FLHRC only.

NOTE

Depending upon model, continue procedure at INSTALLA-

5.

Install the headlamp assembly. See Section 8.11 HEAD-

TION- FLHR/C/S (PART II), INSTALLATION- FLTR (PART

LAMP

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

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

ASSEMBLY, INSTALLATION.

8-130

2006 Touring: Electrical

HOME

5.

Install left side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

Threaded Hole

6.

Repeat steps 4-5 to install right side saddlebag and side

cover.

7.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

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

fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION

(AFTER COMPLETE

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

FRAME GROUND STUD

f2427x8x

REPLACEMENT

Figure 8-169. Remove Seat

1.

Remove seat. See Section 2.25 SEAT, REMOVAL.

2.

Locate threaded hole between ground studs. See Figure

Harness Ground

8-169. Thoroughly scrape away all paint from around

Ring Terminals

Frame

threaded hole.

3

Crossmember

3.

Moving to front of frame crossmember, thoroughly

scrape away all paint on face of threaded boss.

4.

Obtain five parts shown in Figure 8-170.

1

5.

Start hex screw into threaded boss and tighten to 90-120

in-lbs (10.2-13.6 Nm).

5

6.

At rear of frame crossmember, install flat washer and

lockwasher onto threaded end of hex screw. Install hex

4

nut and tighten to 90-120 in-lbs (10.2-13.6 Nm).

2

Boss

7.

If replacing left side ground stud, slide two main harness

ground ring terminals (with orange tape) onto hex screw.

If replacing right side ground stud, install main harness

1.

Hex Screw, 2551W

ground ring terminal (without orange tape) and chassis

2.

Flat Washer, 6703

4.

Hex Nut, 7688

ground ring terminal.

3.

Lock Washer, 7036

5.

Jam Nut, 7689W

8.

Install jam nut onto hex screw and tighten to 50-90 in-

Figure 8-170. Install New Frame Ground Stud

lbs (5.7-10.2 Nm).

9.

Install seat. See Section 2.25 SEAT, INSTALLATION.

8-132

2006 Touring: Electrical

HOME

INTERCONNECT HARNESS

8.35

FLHX, FLHT/C/U

f2254x8x

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. References to left and right always refers to

left and right side of motorcycle.

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2.

Remove the outer fairing and windshield. See Section

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

U), OUTER FAIRING/WINDSHIELD, REMOVAL.

Figure 8-171. Anchor Interconnect Harness in Lower

3.

Release anchors on convoluted tubing of interconnect

Ears of Speedometer/Tachometer Brackets

harness from lower outboard ears of speedometer and

tachometer brackets. See Figure 8-171. For best results,

squeeze anchor with needle nose pliers before pulling

from hole in ear.

e.

Speedometer connector

[39];

12-place Packard

(black); back of speedometer. Unthread rubber boot

4.

Remove anchor on convoluted tubing of headlamp con-

from odometer reset switch and pull switch from

nector from hole in left fairing bracket. See Figure 8-174.

hole in inner fairing.

5.

On opposite side of inner fairing, remove anchor on con-

f.

Tachometer connector

[108];

12-place Packard

duit of fairing cap switch connector from hole in lower

(gray); back of tachometer.

wing of right side radio support bracket. See Figure 8-

175.

g.

Ambient temperature sensor connector

[107], if

present; 3-place Multilock (black); anchored in hole

6.

Cut cable strap to release convoluted tubing of intercon-

on outboard side of left fairing bracket.

nect harness and conduit of main to interconnect har-

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

h.

Left handlebar switch controls connector [24], 12-

bracket. See Figure 8-176.

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

brace (inboard side).

7.

Remove connectors from their retaining devices, if

i.

Left front turn signal/auxiliary lamp connector [31L],

present, and disconnect pin and socket halves. See Fig-

4-place Multilock (black); T-stud on left fairing sup-

ure 8-172.

port brace (outboard side).

a. Main to interconnect harness connector

[2],

12-

j.

Right front turn signal/auxiliary lamp connector

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

[31R], 4-place Multilocks (black); T-stud on right fair-

brace (middle).

ing support brace (outboard side).

b. Main to interconnect harness connector [156], 6-

k.

Main to interconnect harness connector [1],

12-

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

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

brace (inboard side).

bracket.

c. Radio connector [27], 23-place Amp (black); back of

l.

Main to interconnect harness connector [15],

4-

radio (right side).

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

right fairing bracket.

d. Indicator lamps connector [21]; 10-place Multilock

(black); above radio

(between speedometer and

m.

Fairing cap switch connector [105], 12-place Mul-

tachometer gauges).

tilock (black); top of upper fork bracket (right side).

2006 Touring: Electrical

8-133

HOME

[24]

f2356x8x

[1]

[21]

[156]

[108]

[39]

[107]

[31L]

[6]

[2]

[27]

[31R]

[15]

[32]

[105]

[22]

[38]

[22] Right Handlebar Switches

[38] Headlamp

[1] Main to Interconnect Harness

[24] Left Handlebar Switches

[39] Speedometer Gauge

[2] Main to Interconnect Harness

[27] Radio

[105] Fairing Cap Switches

[6] Audio to Interconnect Harness

[31L] Left Front Turn Signal/Aux Lamp

[107] Ambient Temperature Sensor

[15] Main to Interconnect Harness

[31R] Right Front Turn Signal/Aux Lamp

[108] Tachometer Gauge

[21] Indicator Lamps

[32] Front Fender Tip Lamp

[156] Main to Interconnect Harness

Figure 8-172. Inner

Fairing

- Interconnect Harness Connectors (FLHX, FLHT/C/U)

n. Right handlebar switch controls connector [22], 12-

p. Front fender tip lamp jumper harness connector

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

[32],

2-place Multilock

(black); below upper fork

plate (left side).

bracket (left side).

o. Audio to interconnect harness connector

[6], if

present; 6-place Deutsch (black); top of radio (left

8.

See Figure 8-173. Remove connectors from spade con-

side).

tacts as follows:

8-134

2006 Touring: Electrical

HOME

[34]

[110]

[116]

[35]

[111]

[117]

[132]

[112]

[114]

[113]

[115]

f2356x8x

[34] Right Front Speaker

[112] Oil Pressure Gauge Lamp

[35] Left Front Speaker

[113] Oil Pressure Gauge

[116] Fuel Gauge Lamp

[110] Voltmeter Gauge Lamp

[114] Air Temperature Gauge Lamp

[117] Fuel Gauge

[111] Voltmeter Gauge

[115] Air Temperature Gauge

[132] Cigarette Lighter

Figure 8-173. Inner

Fairing - Interconnect Harness Connectors (FLHX, FLHTC/U)

Left side:

Right side:

● Left front speaker [35]

● Right front speaker [34]

● Fuel gauge [117] and lamp [116]

● Voltmeter gauge [111] and lamp [110]

● Cigarette lighter [132]

12. Feed conduit (with orange tape) terminating in right side

speaker and voltmeter gauge connectors to mid section

9.

Feed conduit (with orange tape) terminating in left side

of inner fairing (area between left and right fairing brack-

speaker, fuel gauge, cigarette lighter and front turn sig-

ets). Also feed conduit terminating in main to intercon-

nal connectors to mid section of inner fairing

(area

nect harness connectors [2] and [156] to mid section.

between left and right fairing brackets). Also feed conduit

terminating in left handlebar switch controls connector

13. If present, remove connectors from spade contacts as

[24] to mid section.

follows:

10. Pull harness ground socket terminal from spade contact

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

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

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

11. See Figure 8-173. Remove connectors from spade con-

tacts as follows:

14. Remove interconnect harness from motorcycle.

2006 Touring: Electrical

8-135

HOME

14. Using oval shaped hole in right fairing bracket, install

9421

new cable strap capturing convoluted tubing of intercon-

nect harness and conduit of main to interconnect har-

ness connectors [1], [2], [15] and [156]. See Figure 8-

175 and Figure 8-176.

15. Install the windshield and outer fairing. See Section 2.30

UPPER FAIRING/WINDSHIELD

(FLHX, FLHT/C/U),

OUTER FAIRING/WINDSHIELD, INSTALLATION.

16. Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

Anchor

FLTR

REMOVAL

Figure 8-174. Anchor Convoluted Tubing of

Headlamp Connector

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

9423

2.

Place protective material on top of front fender to protect

paint from scratches or other damage.

3.

Remove the outer fairing and windshield. See Section

2.31 UPPER FAIRING/WINDSHIELD (FLTR), OUTER

FAIRING, REMOVAL.

Anchor

4.

Carefully cut two cable straps to free wire bundles and

conduit from convoluted tubing of interconnect harness

and allow to hang naturally. See Figure 8-179.

Oval Shaped

5.

See Figure 8-177. Disconnect main harness from inter-

Hole

connect harness as follows:

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

place Deutsch (black); below radio (right side).

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

place Deutsch (gray); below radio (right side).

Figure 8-175. Anchor Conduit of Fairing Cap

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

Switch Connector

place Packard (black); below radio (right side).

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

9659

place Deutsch (gray); below radio (right side).

6.

See Figure 8-177. Disconnect handlebar switch controls

from interconnect harness. Disconnect radio and radio

ground. Proceed as follows:

● Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on left side of radio

bracket.

● Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on left side of radio

bracket.

Cable

Strap

NOTE

Push on each handlebar connector to disengage small end

of slot on attachment clip from T-stud on radio bracket. Lift

Figure 8-176. Cable Strap Convoluted Tubing and

connector off T-stud.

Conduit to Fairing Bracket

2006 Touring: Electrical

8-137

HOME

[27]

[24]

[1]

[22]

[156]

Radio

Ground

[2]

[31L]

[31R]

f2362x8x

[15]

[38]

[31L] Left Turn Signal

[1] Main to Interconnect Harness

[22] Right Handlebar Switch Controls

[31R] Right Turn Signal

[2] Main to Interconnect Harness

[24] Left Handlebar Switch Controls

[38] Headlamp

[15] Main to Interconnect Harness

[27] Radio

[156] Main to Interconnect Harness

Figure 8-177. Inner Fairing - Interconnect Harness Connectors (FLTR)

● Radio connector [27], 23-place Amp (black); back of

● Ambient temperature sensor connector [107], 3-

radio (right side).

place Multilock.

● Radio ground; single spade and socket terminal;

below radio (left side).

9.

See Figure 8-178. Draw branches of interconnect har-

7.

Remove left side of instrument nacelle. See Section 2.31

ness (terminating in odometer reset switch and speed-

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

ometer, tachometer, indicator lamps, instrument nacelle

NACELLE, REMOVAL, steps 1-6.

switch and ambient temperature sensor connectors)

8.

See Figure

8-178. Disconnect instrument nacelle

from instrument nacelle through tunnel of fairing bracket

switches and ambient temperature sensor from intercon-

to front of inner fairing. Allow the interconnect harness to

nect harness as follows:

hang along the left side of the front fender.

● Instrument nacelle switch connector [105], 12-place

10. Remove connectors from spade contacts as follows:

Multilock.

8-138

2006 Touring: Electrical

HOME

[21] Indicator Lamps

[105A/B]

[39] Speedometer Gauge

[21]

[105A/B] Instrument Nacelle Switches

[105C/D] Speaker Switch

[107] Ambient Temperature Sensor

[108]

[108] Tachometer Gauge

[39]

[105C/D]

[107]

f2219x8x

Figure 8-178. Instrument Nacelle (Bezel Removed)

Left side:

cable connector

[51] at back of radio

(left side), if

removed.

● Left speaker

● Fuel gauge and lamp (with orange tape)

2.

Install connectors onto spade contacts as follows:

● Air temperature gauge and lamp

Left side:

● Cigarette lighter

● Left speaker

Right side:

● Fuel gauge and lamp (with orange tape)

● Right speaker

● Air temperature gauge and lamp

● Voltmeter gauge and lamp (with orange tape)

● Oil pressure gauge and lamp

● Cigarette lighter; connect the orange/white wire

socket terminal to the socket spade contact, the

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

black wire socket terminal to the shell contact.

and [31R], 3-place Multilocks, from flexible clips on sides

of inner fairing.

Right side:

12. Remove interconnect harness from motorcycle. Remove

● Right speaker

radio antenna cable connector [51] at back of radio (left

side) to facilitate removal.

● Voltmeter gauge and lamp (with orange tape)

● Oil pressure gauge and lamp

INSTALLATION

3.

Find branch of interconnect harness terminating in

odometer reset switch and speedometer, tachometer,

CAUTION

indicator lamps, instrument nacelle switch and ambient

temperature sensor connectors. Feed connectors and

To avoid chafing wires of interconnect harness, verify

conduit from front of inner fairing through tunnel of fair-

that trim strips are installed on hooks of radio bracket.

ing bracket and then out through opening at top of fairing

1.

Center convoluted tubing of interconnect harness above

bracket to instrument nacelle.

and inboard of hooks on radio bracket. See Figure 8-

4.

See Figure 8-178. Connect instrument nacelle switches

179. To verify proper orientation, be sure that long length

and ambient temperature sensor to interconnect har-

of conduit terminating in socket terminals of cigarette

lighter is on left side of motorcycle. Install radio antenna

ness as follows:

2006 Touring: Electrical

8-139

HOME

7.

Orient connectors as shown in Figure 8-177. Install two

9427a

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 mate-

rial. See Figure 8-179.

8.

Capture conduit of front turn signal lamp connectors

[31L] and [31R], 3-place Multilocks, in flexible clips on

sides of inner fairing.

9.

Install the outer fairing and windshield. See Section 2.31

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-

ING, INSTALLATION.

10.

Install left side of instrument nacelle. See Section 2.31

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

NACELLE, INSTALLATION, steps 3-7 and 9-10.

1

2

11.

Install bezel. See BEZEL, INSTALLATION, in this sec-

tion.

Figure 8-179. Cable Strap Convoluted Tubing

12.

Install maxi-fuse. See Section

8.3

SYSTEM FUSES,

and Conduit

MAXI-FUSE, INSTALLATION.

● Instrument nacelle switch connector [105], 12-place

Multilock.

● Ambient temperature sensor connector [107], 3-

place Multilock.

5.

See Figure 8-177. Connect handlebar switch controls to

interconnect harness. Connect radio and radio ground.

Proceed as follows:

● Left handlebar switch controls connector [24], 12-

place Deutsch (gray); T-stud on left side of radio

bracket.

● Right handlebar switch controls connector [22], 12-

place Deutsch (black); T-stud on left side of radio

bracket.

NOTE

Place large end of slot on attachment clip over T-stud on

radio bracket and push on each handlebar connector to

engage small end of slot.

● Radio connector [27], 23-place Amp (black); back of

radio (right side).

● Radio ground; single spade and socket terminal;

below radio (left side).

6.

See Figure 8-177. Connect main harness to intercon-

nect harness as follows:

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

place Deutsch (black); below radio (right side).

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

place Deutsch (gray); below radio (right side).

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

place Packard (black); below radio (right side).

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

place Deutsch (gray); below radio (right side).

8-140

2006 Touring: Electrical

HOME

RADIO ANTENNA CABLE

8.36

7.

Starting at the front of the wire trough, and working rear-

FLHTC/U

ward from side to side, release catches to remove cover.

For most catches, carefully insert blade of flat tip screw-

driver into slot only as far as necessary to release catch.

REMOVAL

8.

Carefully cut three cable straps securing main harness

(and audio harness on FLHTCU) to left upper frame

1.

Remove fuel tank. For carbureted models, see Section

tube and luggage rack rail.

4.7 FUEL TANK

(CARBURETED), COMPLETE

REMOVAL, FLHX, FLHT. For fuel injected models, see

9.

Open Tour-Pak and proceed as follows:

Section

9.4 FUEL TANK (FUEL INJECTED), COM-

FLHTC: Remove rubber mat.

PLETE REMOVAL, FLHXI, FLHT/C/U/I, FLTRI.

FLHTCU: Open map pocket and remove acorn nuts

2.

Remove left side saddlebag. See Section 2.26 SAD-

(with flat washers). Remove map pocket and molded

DLEBAG, REMOVAL.

liner from Tour-Pak.

3.

Gently pull side cover from frame downtubes (no tools

10.

On Ultra models, depress external latch and remove

required).

bulb socket from left side wrap-around light.

4.

Remove the outer fairing and windshield. See Section

11.

Rotate knurled ring in a counterclockwise direction to

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

separate pin and socket halves of radio antenna cable

U), OUTER FAIRING/WINDSHIELD, REMOVAL.

connector [51]. Release cable from two adhesive clips at

bottom of Tour-Pak.

5.

Remove radio antenna cable connector [51] at back of

radio (left side). See Figure 8-180. Carefully cut cable

12.

Disconnect Tour-Pak lights connector [12], 3-place Mul-

where it exits main harness conduit.

tilock. See Figure 8-181.

6.

Remove screw, ground wire ring terminal and P-clamp to

13.

Pull grommet into Tour-Pak and remove from main har-

release main harness (and audio harness on FLHTCU)

ness conduit.

from right side of steering head.

14.

Pull Tour-Pak lights and radio antenna cable connectors

through hole at front of Tour-Pak. See Figure 8-182.

15.

Carefully cut radio antenna cable where it exits main

harness conduit.

Radio Antenna

Cable [51]

INSTALLATION

NOTE

Place new radio antenna cable on motorcycle following origi-

nal path. Note that the cable follows the main harness routed

to the rear left side of the motorcycle.

1.

At front of inner fairing, connect radio antenna cable

connector [51] at back of radio (left side). See Figure 8-

180.

2.

Route free end of radio antenna cable rearward under

the fairing cap to right side of the steering head.

3.

Capture radio antenna cable, main harness (and audio

harness on FLHTCU) in P-clamp. Install ground wire

ring terminal on screw and fasten P-clamp to right side

of steering head.

f2356x8x

4.

Route radio antenna cable rearward through opening at

Figure 8-180. Remove Outer

Fairing (FLHX, FLHTC/U)

front of wire trough. Exiting wire trough through opening

2006 Touring: Electrical

8-141

HOME

6.

Feed Tour-Pak lights and radio antenna cable connec-

tors and conduit through hole at front of Tour-Pak. Cap-

f2421x8x

ture cable and conduit in grommet. Install grommet in

hole with the larger OD facing inside.

4

7.

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

tilock. See Figure 8-181.

8.

Rotate knurled ring in a clockwise direction to mate pin

and socket halves of radio antenna cable connector [51].

1

Capture cable in two adhesive clips at bottom of Tour-

Pak.

9.

On Ultra models, install bulb socket of left side wrap-

around light.

3

10.

Tighten three cable straps securing radio antenna cable

2

to left upper frame tube and luggage rack rail. Cut any

excess cable strap material.

11.

Proceed as follows:

1.

Radio Antenna Cable

FLHTC: Install rubber mat in Tour-Pak. Close Tour-Pak.

2.

Adhesive Clip

FLHTCU: Install molded liner in Tour-Pak. Install map

3.

Tour-Pak Lights Connector [12]

pocket and secure using acorn nuts (with flat washers).

4.

Grommet

Close Tour-Pak.

Figure 8-181. Disconnect Tour-Pak Lights Connector

12.

Place cover over wire trough. Starting at the front and

working rearward from side to side, engage catches to

latch cover. Verify that all latches are fully engaged.

f2422x8x

13.

Install fuel tank. For carbureted models, see Section 4.7

4

FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHX, FLHT. For fuel injected

2

models, see Section

9.4 FUEL TANK

(FUEL

INJECTED), INSTALLATION

(AFTER COMPLETE

REMOVAL), FLHXI, FLHT/C/U/I, FLTRI.

14.

Install the outer fairing and windshield. See Section 2.31

1

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-

ING, INSTALLATION.

15.

Align barbed studs in left side cover with grommets in

frame downtubes and push firmly into place (no tools

required).

16.

Install left side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

3

1.

Adhesive Clip

2.

Radio Antenna Cable Connector [51D]

3.

Grommet

Frame

f2425x8x

4.

Tour-Pak Hole

Backbone

Figure 8-182. Feed Main Harness Thru Tour-Pak Hole

Saddlebag

Guard

1

at end of left leg, route cable rearward along bottom of

upper frame tube to rear of battery box, up through

opening between rear of frame weldment and front of

2

rear fender, along inboard side of upper frame tube (and

chrome frame tube cover) and then up the luggage rack

rail to front of Tour-Pak.

5.

Loosely install two new cable straps to secure radio

1

2

Captures radio antenna cable, main harness, audio

harness (FLHTCU only), console pod conduit (FLHTCU

antenna cable to left upper frame tube. See Figure 8-

only) and upper frame tube.

183. Loosely install new cable strap to secure radio

antenna cable to luggage rack rail.

Figure 8-183. Capture Radio Antenna Cable

8-142

2006 Touring: Electrical

HOME

FLHX, FLTR

Radio Antenna

Cable [51]

REMOVAL

1.

Remove fuel tank. See Section 9.4 FUEL TANK (FUEL

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

U/I, FLTRI.

2.

Remove left side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

3.

Gently pull side cover from frame downtubes (no tools

required).

4.

Remove the outer fairing and windshield. See Section

2.31 UPPER FAIRING/WINDSHIELD (FLTR), OUTER

FAIRING, REMOVAL.

5.

Remove radio antenna cable connector [51] at back of

radio (left side). See Figure 8-184. Carefully cut cable

where it exits main harness conduit.

6.

Remove screw, ground wire ring terminal and P-clamp to

f2362x8x

release main harness from right side of steering head.

Figure 8-184. Remove Outer Fairing

(FLTR)

7.

Starting at the front of the wire trough, and working rear-

ward from side to side, release catches to remove cover.

For most catches, carefully insert blade of flat tip screw-

2.

Proceed as follows:

driver into slot only as far as necessary to release catch.

8.

Carefully cut two cable straps securing main harness

FLHX: Route free end of radio antenna cable rearward

conduit to left upper frame tube.

under the fairing cap to right side of the steering head.

9.

On left side of motorcycle, remove bolt (with flat washer)

FLTR: Route free end of radio antenna cable rearward

to remove passenger seat strap and saddlebag front

through opening on the right side of the fairing bracket to

mounting bracket from chrome frame tube cover.

right side of the steering head.

10.

Remove Phillips screw and chrome frame tube cover.

3.

Capture radio antenna cable and main harness in P-

11.

Carefully cut cable strap to release radio antenna cable

clamp. Install ground wire ring terminal on screw and

from shoulder of upper frame tube (just in front of air

fasten P-clamp to right side of steering head.

valve mounting bracket). Cut cable strap to release radio

antenna cable from slotted hole in rear fender support.

4.

Route radio antenna cable rearward through opening at

front of wire trough. Exiting wire trough at end of left leg,

See Figure 8-185.

route cable rearward along bottom of upper frame tube

12.

At bottom of radio antenna bracket, rotate knurled ring to

to rear of battery box, and then up through opening

separate pin and socket halves of radio antenna cable

between rear of frame weldment and front of rear fender,

connector [51].

continuing along inboard side of upper frame tube (and

13.

Draw radio antenna cable forward to area of fuse block

chrome frame tube cover).

bracket. Carefully cut cable where it exits main harness

5.

Loosely install two new cable straps to secure radio

conduit.

antenna cable to left upper frame tube. See Figure 8-

183.

6.

Install new cable strap to secure radio antenna cable

INSTALLATION

(and rear facia lamp wires on FLHX) to shoulder of

upper frame tube (just in front of rear shock air valve

NOTE

mounting bracket). Using slotted hole, install new cable

Place new radio antenna cable on motorcycle following origi-

strap to secure radio antenna cable (and rear facia lamp

nal path. Note that the cable follows the main harness routed

wires on FLHX) to rear fender support. See Figure 8-185

to the rear left side of the motorcycle.

or Figure 8-186.

1.

At front of inner fairing, connect radio antenna cable

7.

At bottom of radio antenna bracket, rotate knurled ring to

connector [51] at back of radio (left side). See Figure 8-

mate pin and socket halves of radio antenna cable con-

184.

nector [51].

2006 Touring: Electrical

8-143

HOME

11. Place cover over wire trough. Starting at the front and

1

9425

working rearward from side to side, engage catches to

latch cover. Verify that all latches are fully engaged.

12. Install fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION

(AFTER COMPLETE

REMOVAL), FLHXI, FLHT/C/U/I, FLTRI.

13. Install the outer fairing and windshield. See Section 2.31

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-

ING, INSTALLATION.

14. Align barbed studs in left side cover with grommets in

frame downtubes and push firmly into place (no tools

required).

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

2

BAG, INSTALLATION.

16. Using an open end/box wrench, tighten saddlebag front

Figure 8-185. Capture Radio Antenna Cable (FLTR)

mounting bracket bolt to 60-96 in-lbs (6.8-10.8 Nm).

9364

Figure 8-186. Capture Radio Antenna Cable (FLHX)

8.

Tighten four cable straps securing radio antenna cable

to left upper frame tube and rear fender support. Cut any

excess cable strap material.

9.

Install chrome frame tube cover on frame tube. Install

Phillips screw and tighten to 25-40 in-lbs (2.8-4.5 Nm).

10. Insert bolt

(with flat washer) through passenger seat

strap and slotted hole of saddlebag front mounting

bracket. Insert bolt into forward hole in chrome frame

tube cover. Snug saddlebag front mounting bracket bolt,

but do not tighten.

8-144

2006 Touring: Electrical

HOME

AUDIO HARNESS (FLHTCU)

8.37

REMOVAL

f2423x8x

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

3

REMOVAL, FLHX, FLHT. For fuel injected models, see

Section

9.4 FUEL TANK (FUEL INJECTED), COM-

PLETE REMOVAL, FLHXI, FLHT/C/U/I, FLTRI.

2.

Remove right side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

3.

Gently pull side cover from frame downtubes (no tools

required).

2

4.

Repeat steps 2 and 3 on left side of motorcycle.

4

5.

Remove the outer fairing and windshield. See Section

1

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

U), OUTER FAIRING/WINDSHIELD, REMOVAL.

1.

CB Antenna Cable Connector [50]

6.

See Figure 8-187. Disconnect the following connectors:

2.

Adhesive Clip

a. CB antenna cable connector [50], back of CB mod-

3.

Grommet

ule (right side).

4.

Tour-Pak Mounting Bolt

Figure 8-188. Disconnect CB Antenna Cable Connector

[6]

[50]

b. Audio to interconnect harness connector

[6],

6-

[184]

place Deutsch (black); top of radio (left side).

[28]

c. Radio connector [28], 35-place Amp (black); back of

radio (left side).

d. CB module connector

[184],

12-place Deutsch

(black); top of radio (left side).

7.

Remove screw, ground wire ring terminal and P-clamp to

release main harness and audio harness from right side

of steering head.

8.

Carefully pull front section of audio harness rearward

under right side of fairing cap and allow conduit and con-

nectors to hang over top of engine guard.

9.

Open Tour-Pak. Open map pocket and remove acorn

nuts. Remove map pocket and molded liner from Tour-

Pak.

10.

Disconnect CB antenna cable connector [50]. Release

cable from front adhesive clip inside Tour-Pak. See Fig-

ure 8-188.

11.

Pull right side grommet into Tour-Pak and remove from

f2356x8x

CB antenna cable. Feed CB antenna cable through hole

[6] Audio to Interconnect Harness

at front of Tour-Pak.

[28] Radio

12.

Remove trim ring and gently pull on wire harness to

[50] CB Antenna Cable

draw rear speaker/passenger controls connector [41], 6-

[184] CB Module

place Deutsch, out of right side speaker box. Depress

external latch and use a rocking motion to separate pin

Figure 8-187. Remove Outer Fairing (FLHTCU)

and socket halves.

2006 Touring: Electrical

8-145

HOME

21. Draw a line on the conduit and/or wire bundle on both

Console Pod

sides of cable straps 1, 2, 4, 6 and 11-17

Connector [53]

NOTE

Do not tamper with the cable straps that fix the position of the

breakouts. The breakouts are those branches of the main

harness that exit the wire trough on the left and right sides

(cable straps 3 and 7-10 in Figure 8-190). As exact place-

ment of the breakouts is necessary for optimal fit and routing,

they should be left intact whenever possible.

22. Carefully cut and remove cables straps marked with the

paint pen.

23. Gently pull on audio harness to separate from the main

harness. If a few strands of the audio harness are inter-

woven or intermingled with wires of the main harness

and cannot be separated, then proceed based on

whether the audio harness is to be discarded or

retained.

Discarded

f2192x8x

a. Cut audio harness wires well away from those of the

Figure 8-189. Remove Seat

main harness to avoid cutting or nicking the main

harness wires.

13.

Carefully draw rear right section of audio harness for-

ward allowing conduit and connectors to hang beside

Table 8-21. Wire Trough Cable Straps

the right side passenger footboard.

Cable

Captures

14.

Moving to opposite side of motorcycle, remove trim ring

Models

Strap

Conduit/Wire Bundle

and gently pull on wire harness to draw rear speaker/

passenger controls connector [42], 6-place Deutsch, out

1

Main Harness

All

of left side speaker box. Depress external latch and use

2

Audio Harness

FLHTCU

a rocking motion to separate pin and socket halves.

Ignition Coil

All

15.

Release rear headset receptacle from bracket at bottom

3

of left side speaker box. Release spring from hole in

Fuel Gauge

FLHR/C/S

receptacle wire jacket.

Main Harness

All

4

16.

Carefully draw rear left section of audio harness forward

Audio Harness

FLHTCU

to front of rear fender and then pull out from beneath

5

Main Harness

All

upper frame tube allowing conduit and connectors to

hang beside the left side passenger footboard.

Main Harness

All

6

17.

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

Audio Harness

FLHTCU

from attachment clip anchored in hole of frame weld-

7

Front Fuel Injector

Fuel Injected

ment at rear of battery box. See Figure 8-189. Depress

TP Sensor, MAP Sensor,

external latches and use a rocking motion to separate

Fuel Injected

IAC and Rear Fuel Injector

8

pin and socket halves.

MAP Sensor

Carbureted

18.

Carefully cut three cable straps securing audio harness

TP Sensor, MAP Sensor,

to left and right upper frame tubes. See Figure 8-191.

9

Fuel Injected

IAC and Rear Fuel Injector

Cut two cable straps securing audio harness to luggage

rack rails.

Horn

All

10

19.

Starting at the front of the wire trough, and working rear-

ET Sensor

Fuel Injected

ward from side to side, release catches to remove cover.

Main Harness

All

For most catches, carefully insert blade of flat tip screw-

11-17

Audio Harness

FLHTCU

driver into slot only as far as necessary to release catch.

18

Instrument Console

FLHR/C/S

20.

Using a paint pen, draw a line where the audio harness

conduit enters the wire trough at the front and also

19

Fuel Tank Harness

FLHX, FLHT/C/U, FLTR

where it exits the outboard sides of both the left and right

20-21

Main Harness

All

legs at the rear.

8-146

2006 Touring: Electrical

Content      ..     27      28      29      30     ..