Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 33
HOME
5.
Gently apply pressure to handles of tool until crimpers
just secure the core crimp tails.
SEALED TERMINAL
6.
Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze
Core Crimp
bare wire strands, while long pair is positioned over the
insulation or seal material.
7.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.
8.
See Figure B-36. Determine the correct die or nest for
Seal Crimp
the insulation/seal crimp.
Seal
f1006a8x
9.
Position the insulation/seal crimp on the appropriate
nest. Be sure the insulation/seal crimp tails are facing
Insulation
f1005a8x
the forming jaws.
Crimp
Core Crimp
10. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete.
11. Inspect the quality of the core and insulation/seal
crimps. Distortion should be minimal. See Figure B-37.
Insulation
NON-SEALED TERMINAL
Figure B-37. Inspect Core and Insulation/Seal Crimps
B-24
Appendix B
HOME
AUTOFUSE ELECTRICAL CONNECTOR
B.5
GENERAL
8821
Use these instructions to service the following connector:
● Ignition Light/Key Switch [33B]
DISASSEMBLY
1.
Obtain terminal pick
(Snap-on® GA500A) like that
shown Figure B-38.
2.
Insert smallest pair of pins into chamber on mating end
of socket housing to depress tangs on each side of ter-
minal simultaneously.
Figure B-38. Depress Tangs and Remove Terminal
3.
Gently pull on wire to remove terminal from wire end of
socket housing.
4.
If necessary, crimp new terminals on wires.
ASSEMBLY
1.
Using a thin flat blade, like that on an X-Acto knife, care-
fully bend tang on each side of terminal outward away
from terminal body.
2.
With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it
locks in place.
Appendix B B-25
HOME
SEALED BUTT SPLICE CONNECTORS
B.6
8.
Repeat steps 5-7 on the other side of the butt splice con-
PROCEDURE
nector.
Butt splicing may be a necessary procedure for the replace-
NOTE
ment of some components. Proceed as follows:
If adjacent wires are being spliced, stagger the splices so
1.
Strip 3/8 inch (9.5 mm) of insulation off the ends of the
that the butt splice connectors are spaced at different posi-
wires.
tions along the length of the wires.
2.
Compress the handles of the Packard Crimp Tool (HD-
38125-8) until the ratchet automatically opens.
9.
Using the UltraTorch UT-100 (HD-39969), Robinair Heat
3.
Since the size of the connectors vary with the gauge of
Gun
(HD-2507
the wire, reference the following table to ensure properly
41183) or other suitable radiant heating device, heat the
sealed splices are used.
crimped splice to encapsulate the butt splice connection.
Apply heat from the center of the crimp out to each end
until the meltable sealant exudes out both ends of the
Gauge
Connector
Part
connector. See Figure B-40.
Wire
Color
Number
18-20
Red
P/N 70585-93
14-16
Blue
P/N 70586-93
Red
10-12
Yellow
P/N 70587-93
4.
Determine the correct die or nest for the crimping opera-
Blue
tion. Match the color or gauge wire marked on the butt
splice connector with the corresponding crimp cavity on
the crimp tool. See Figure B-39.
5.
Gently apply pressure to the handles until the crimper
lightly secures one side of the metal insert inside the butt
splice connector. The connector must be crimped in two
Yellow
stages, one side and then the other.
6.
See Figure B-40. Feed the wire into the butt splice con-
nector until the stripped end contacts the wire stop
inside the metal insert.
7.
Squeeze the handles of the crimp tool until tightly
closed. The tool automatically opens when the crimping
se-quence is complete.
Figure B-39. Packard Crimp Tool (HD-38125-8)
Wire
Metal
Melted Sealant
Stop
Insert
Insert stripped wire
Crimp wire ends
Apply heat and allow
ends into connector
in connector
connector to cool
f1203b8x
Figure B-40. Installing Sealed Butt Splice Connectors
B-26
Appendix B
HOME
NOTE
1WARNING
It is acceptable for the splice to rest against the heat shrink
tool attachment.
Be sure to follow manufacturer's instructions when
using the UltraTorch UT-100 or any other radiant heating
10. Heat the center of the splice until the crimp indentations
device. Failure to follow manufacturer's instructions can
disappear and the tubing assumes a smooth cylindrical
cause a fire, which could result in death or serious
appearance.
injury. (00335a)
● Avoid directing heat toward any fuel system compo-
nent. Extreme heat can cause fuel ignition/explosion
resulting in death or serious injury.
● Avoid directing heat toward any electrical system
component other than the connectors on which heat
shrink work is being performed.
● Always keep hands away from tool tip area and heat
shrink attachment.
Appendix B B-27
HOME
ELECTRICAL CONNECTOR LOCATIONS
B.7
FLHX, FLHT/C/U
No.
Description
Type
Location
Fig.
[1]
Main to Interconnect Harness
12 - Place Deutsch (Black)
Inner Fairing - Right Radio Support Bracket
41
[2]
Main to Interconnect Harness
12 - Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
41
[4]
Accessory
4 - Place Deutsch
Uppe
46
[5]
Maxi-Fuse
2 - Place Packard
Under Left Side Cover
43
[6]
Audio to Interconnect Harness
6 - Place Deutsch (Gray)
Inner Fairing - Top of Radio (Left Side)
41
[7]
Rear Fender Lights Harness
8 - Place Multilock
Top of Rear Fender (Under Seat)
49
[10]
ICM ****
12 - Place Deutsch (Black)
Under Right Side Cover
48
[12]
Tour-Pak Lights (Rear Facia Lamp on FLHX)
3 - Place Multilock
Inside Tour-Pak (Inboard of Upper Frame Tube on FLHX)
42
[13]
Fuel Tank Harness
4 - Place Multilock
Behind Fuel Tank (Under Seat)
47
[15]
Main to Interconnect Harness
4 - Place Packard
Inner Fairing - Right Fairing Bracket
41
[17]
Cruise Control Module **
10 - Place Packard
Under Left Side Cover
43
[18]
Left Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[19]
Right Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[21]
Indicator Lamps
10 - Place Multilock
Inner Fairing - Above Radio
41
[22]
Interconnect to Right Handlebar Switches
12 - Place Deutsch (Black)
Inner Fairing - Fork Stem Nut Lock Plate (Left Side)
41
[24]
Interconnect to Left Handlebar Switches
12 - Place Deutsch (Gray)
Inner Fairing - Left Fairing Support Brace
41
[27]
Radio *
23 - Place Amp
Inner Fairing - Back of Radio (Right Side)
41
[28]
Radio **
35 - Place Amp
Inner Fairing - Back of Radio (Left Side)
41
[30]
TSM/TSSM
12 - Place Deutsch
Cavity in Crossmember at Rear of Battery Box (Under Seat)
52
[31L]
Left Front Turn Signal/Auxiliary Lamp
4 - Place Multilock
Inner Fairing - Left Fairing Support Brace (Outboard Side)
41
[31R]
Right Front Turn Signal/Auxiliary Lamp
4 - Place Multilock
Inner Fairing - Right Fairing Support Brace (Outboard Side)
41
[32]
Front Fender Tip Lamp Jumper Harness (DOM)
2 - Place Multilock (Black)
Inner Fairing - Below Upper Fork Bracket (Left Side)
41
[33]
Ignition/Light Key Switch
3 - Place Packard
Inner Fairing - Under Radio (Front of Ignition Switch Housing)
41
[34]
Right Front Speaker
Spade Contacts
Back of Speaker
-
[35]
Left Front Speaker
Spade Contacts
Back of Speaker
-
[38]
Headlamp
Headlamp Connector
Inner Fairing
41
[39]
Speedometer
12 - Place Packard (Black)
Inner Fairing (Back of Speedometer)
41
[41]
Rear Right Speaker/Passenger Controls **
6 - Place Deutsch
Inside Rear Right Speaker Box
-
[42]
Rear Left Speaker/Passenger Controls **
6 - Place Deutsch
Inside Rear Left Speaker Box
-
[45]
Rear Fender Tip Lamp (DOM)
3 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[46]
Stator
3 - Place Lyall
Bottom of Voltage Regulator (Left Side)
51
[50]
CB Antenna Cable **
-
Inner Fairing - Back of CB Module
41,42
[51]
Radio Antenna Cable *
-
Inner Fairing - Back of Radio (Left Side)
41
[53]
Console Pod **
12 - Place Deutsch
Rear of Battery Box (Under Seat)
52
[64]
Fuse Block
Packard
Under Left Side Cover
43,44
[65]
VSS
3 - Place Deutsch
Under Right Side Cover (Behind Electrical Bracket)
45
[75]
Cruise Roll-Off Switch
Spade Contacts
Right Side of Steering Head
-
[76]
Passenger Headset
7 - Place DIN
Below Rear Left Speaker Box
-
[77]
Voltage Regulator
2 - Place Lyall
Bottom of Voltage Regulator (Right Side)
51
[78]
ECM ***
36 - Place Packard
Under Right Side Cover
45
[79]
CKP Sensor
2 - Place Deutsch
Bottom of Voltage Regulator
51
[80]
MAP Sensor
3 - Place Packard
Top of Intake Manifold/Induction Module
-
[83]
Ignition Coil
4 - Place Delphi
Below Fuel Tank (Left Side)
-
[84]
Front Injector ***
2 - Place Delphi
Below Fuel Tank (Left Side)
-
[85]
Rear Injector ***
2 - Place Delphi
Below Fuel Tank (Left Side)
-
[87]
IAC ***
4 - Place Delphi
Below Fuel Tank (Right Side)
-
[88]
TP Sensor ***
3 - Place Delphi
Below Fuel Tank (Right Side)
-
FLHX, FLHT/C/U Continued ...
B-28
Appendix B
HOME
f2356x8x
[24]
[1]
[21]
[6]
[156]
[108]
[39]
[107]
[31L]
[50]
[2]
[31R]
[184]
[15]
[51]
[28]
[105]
[32]
[38]
[27]
[33]
[22]
[39] Speedometer Gauge
[1] Main to Interconnect Harness
[27] Radio
[50] CB Antenna Cable
[2] Main to Interconnect Harness
[28] Radio
[51] Radio Antenna Cable
[6] Audio to Interconnect Harness
[31L] Left Front Turn Signal/Aux Lamp
[105] Fairing Cap Switches
[15] Main to Interconnect Harness
[31R] Right Front Turn Signal/Aux Lamp
[107] Ambient Temperature Sensor
[21] Indicator Lamps
[32] Front Fender Tip
[108] Tachometer Gauge
[22] Right Handlebar Switches
[33] Ignition Switch
[156] Main to Interconnect Harness
[24] Left Handlebar Switches
[38] Headlamp
[184] CB Module
Figure B-41. Inner Fairing Connectors (FLHX, FLHT/C/U)
Appendix B B-29
HOME
FLHX, FLHT/C/U (Continued)
No.
Description
Type
Location
Fig.
[89]
IAT Sensor ***
2 - Place Delphi
Below Fuel Tank (Right Side)
-
[90]
ET Sensor ***
2 - Place Delphi
Back of Front Cylinder (Left Side)
-
[91]
Data Link
4 - Place Deutsch
Under Right Side Cover
45
[93]
Tail Lamp
4 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[94]
Rear Fender Lights Harness to Circuit Board
6 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[105]
Fairing Cap Switches
12 - Place Multilock
Inner Fairing - Above Upper Fork Bracket (Right Side)
41
[107]
Ambient Air Temperature Sensor *
3 - Place Multilock
Inner Fairing - Left Fairing Bracket (Outboard Side)
41
[108]
Tachometer
12 - Place Packard (Gray)
Inner Fairing (Back of Tachometer)
41
[110]
Voltmeter Lamp
Spade Connector
Inner Fairing
-
[111]
Voltmeter
Spade Connector
Inner Fairing
-
[112]
Oil Pressure Gauge Lamp
Spade Connector
Inner Fairing
-
[113]
Oil Pressure Gauge
Spade Connector
Inner Fairing
-
[114]
Air Temperature Gauge Lamp
Spade Connector
Inner Fairing
-
[115]
Air Temperature Gauge
Spade Connector
Inner Fairing
-
[116]
Fuel Gauge Lamp
Spade Connector
Inner Fairing
-
[117]
Fuel Gauge
Spade Connector
Inner Fairing
-
[119]
EFI Fuses ***
Fuse Terminals
Fuse Block (Under Right Side Cover)
45
[121]
Rear Brake Light Switch
Spade Terminals
Beneath Transmission (Right Side)
-
[122]
Horn
Spade Terminals
Between Cylinders (Left Side)
-
[123]
Starter Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
52
[124]
Brake Light Relay
Relay Connector
Fuse Block (Under Left Side Cover)
44
[126]
Ignition Keyswitch Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
52
[128]
Starter Solenoid
Spade Terminals
Top of Starter
-
[129]
Harness Grounds
Ring Terminals
Upper Frame Cross Member (Under Seat)
46
[131]
Neutral Switch
Post Terminals
Transmission Top Cover
-
[132]
Cigarette Lighter *
Spade Terminals
Inner Fairing
-
[135]
EFI System Relay ***
Relay Connector
Fuse Block (Under Right Side Cover)
45
[139]
Oil Pressure Sender
4 - Place Delphi
Front Right Crankcase
-
[141]
Fuel Level Sender (and Fuel Pump on EFI models)
4 - Place Packard
Top of Canopy (Under Console)
-
[142]
Security Siren (Optional)
3 - Place Delphi
Under Right Side Cover (Behind Electrical Bracket)
45
[143]
Front Fender Tip Lamp (DOM)
2 - Place Multilock (Black)
Under Front Fender Tip Lamp Bracket
-
[156]
Main to Interconnect Harness
6 - Place Deutsch
Inner Fairing - Right Fairing Support Brace
41
[160]
B+
1 - Place Packard
Upper Frame Cross Member (Under Seat)
46
[184]
CB Module
12 - Place Deutsch
Inner Fairing - Top of Radio (Left Side)
41
* Classic and Ultra
** Ultra Only
*** Fuel Injected Models
**** Carbureted Models
f2421x8x
f2423x8x
CB Antenna
Tour-Pak Lights
Cable Connector
Connector [12]
LEFT SIDE
RIGHT SIDE
[50C/D]
Figure B-42. Tour-Pak Connectors
B-30
Appendix B
HOME
f2206x8x
4
6
5
1.
Maxi-Fuse Holder [5]
2.
Fuse Block [64]
3.
Spare Fuse Holder
3
4.
Cruise Module
5.
Cruise Module Connector [17]
6.
Cruise Cable Connector
1
2
Figure B-43. Cruise Control Module (Under Left Side Cover)
f2203x8x
f2377x8x
[142]
[91]
8
7
9
6
10
5
11
4
1
2
3
1.
Headlamp
7.
Radio Power*
[65]
2.
Ignition
8.
Accessory
3.
Lighting
9.
Battery
[119]
[78]
4.
Instruments
10. Brake Light Relay
[65] VSS*
5.
Brakes/Cruise
11. P&A
[78] ECM
6.
Radio Memory*
[91] Data Link
[119] EFI Fuse Block
*Absent from FLHR/C/S models.
[142] P&A Security Siren*
* Under Bracket
Figure B-44. Fuse Blocks - FLHX, FLHTC/U, FLTR
Figure B-45. Under Right Side Cover (Fuel Injected)
(Under Left Side Cover)
Appendix B B-31
HOME
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 B-46. Electrical Connectors - Upper Frame Cross Member (Under Seat)
f2385x8x
f2375x8x
[91]
Fuel Tank Harness
Connector [13]
[10] ICM
(Not Present on FLHR/C/S)
[10]
[91] Data Link
Figure B-47. Rear of Fuel Tank (Under Seat)
Figure B-48. Under Right Side Cover (Carbureted)
B-32
Appendix B
HOME
f2013x8x
f2416x8x
Rear Fender
Lights Connector [7]
[77]
[79]
[46] Stator
[46]
[77] Voltage Regulator
[79] CKP Sensor
Figure B-49. Rear Fender (Under Seat)
Figure B-51. Voltage Regulator (Left Side View)
[126]
[45]
[123]
[19]
[18]
[93]
[94]
[53]
f2192x8x
f2172x8x
[30]
[18] Left Turn Signal Lamp
[19] Right Turn Signal Lamp
[30] TSM/TSSM
[45] Fender Tip Lamp
[53] Console Pod
[93] Tail Lamp
[123] Starter Relay
[94] Fender Lights Harness
[126] Ignition Keyswitch Relay
Figure B-50. Rear Fender Lights Assembly
Figure B-52. Electrical Connectors/Relays (Under Seat)
Appendix B B-33
HOME
FLTR
No.
Description
Type
Location
Fig.
[1]
Main to Interconnect Harness
12 - Place Deutsch (Black)
Inner Fairing - Below Radio (Right Side)
54
[2]
Main to Interconnect Harness
12 - Place Deutsch (Gray)
Inner Fairing - Below Radio (Right Side)
54
[4]
Accessory
4 - Place Deutsch
Upper Frame Cross Member (Under Seat)
46
[5]
Maxi-Fuse
2 - Place Packard
Under Left Side Cover
43
[7]
Rear Fender Lights Harness
8 - Place Multilock
Top of Rear Fender (Under Seat)
49
[10]
ICM ****
12 - Place Deutsch (Black)
Under Right Side Cover
48
[13]
Fuel Tank Harness
4 - Place Multilock
Behind Fuel Tank (Under Seat)
47
[15]
Main to Interconnect Harness
4 - Place Packard
Inner Fairing - Below Radio (Right Side)
54
[17]
Cruise Control Module
10 - Place Packard
Under Left Side Cover
43
[18]
Left Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[19]
Right Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[21]
Indicator Lamps
10 - Place Multilock
Inside Instrument Nacelle (Under Bezel)
53
[22]
Interconnect to Right Handlebar Switches
12 - Place Deutsch (Black)
Inner Fairing - Left Side of Radio Bracket
54
[24]
Interconnect to Left Handlebar Switches
12 - Place Deutsch (Gray)
Inner Fairing - Left Side of Radio Bracket
54
[27]
Radio
23 - Place Amp
Inner Fairing - Back of Radio (Right Side)
54
[30]
TSM/TSSM
12 - Place Deutsch (Gray)
Cavity at Rear of Battery Box (Under Seat)
52
[31L]
Left Front Turn Signal
3 - Place Multilock
Inner Fairing - Left Side
54
[31R]
Right Front Turn Signal
3 - Place Multilock
Inner Fairing - Right Side
54
[33]
Ignition/Light Key Switch
3 - Place Packard
Front of Ignition Switch Housing
-
[34]
Right Front Speaker
Spade Contacts
Back of Speaker
-
[35]
Left Front Speaker
Spade Contacts
Back of Speaker
-
[38]
Headlamp
Headlamp Connector
Inner Fairing
54
[39]
Speedometer
12 - Place Packard (Black)
Inside Instrument Nacelle (Back of Speedometer)
53
[45]
Rear Fender Tip Lamp (DOM)
3 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[46]
Stator
3 - Place Lyall
Bottom of Voltage Regulator (Left Side)
51
FLTR Continued ...
[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 B-53. Instrument Nacelle Connectors (FLTR)
B-34
Appendix B
HOME
FLTR (Continued)
No.
Description
Type
Location
Fig.
[51]
Radio Antenna Cable
-
Inner Fairing - Back of Radio (Left Side)
54
[64]
Fuse Block
Packard
Under Left Side Cover
43,44
[65]
VSS
3 - Place Deutsch
Under Right Side Cover (Behind Electrical Bracket)
45
[75]
Cruise Roll-Off Switch
Spade Contacts
Right Side of Steering Head
-
[77]
Voltage Regulator
2 - Place Lyall
Bottom of Voltage Regulator (Right Side)
51
[78]
ECM ***
36 - Place Packard
Under Right Side Cover
45
[79]
CKP Sensor
2 - Place Deutsch
Bottom of Voltage Regulator
51
[80]
MAP Sensor
3 - Place Packard
Top of Intake Manifold/Induction Module
-
[83]
Ignition Coil
4 - Place Delphi
Below Fuel Tank (Left Side)
-
[84]
Front Injector ***
2 - Place Delphi
Below Fuel Tank (Left Side)
-
[85]
Rear Injector ***
2 - Place Delphi
Below Fuel Tank (Left Side)
-
[87]
IAC ***
4 - Place Delphi
Below Fuel Tank (Right Side)
-
FLTR Continued ...
[24]
f2362x8x
[51]
[1]
[27]
[22]
[156]
Radio
Ground
[2]
[31L]
[31R]
[15]
[38]
[1] Main to Interconnect Harness
[24] Left Handlebar Switches
[2] Main to Interconnect Harness
[27] Radio
[38] Headlamp
[15] Main to Interconnect Harness
[31L] Left Turn Signal
[51] Radio Antenna Cable
[22] Right Handlebar Switches
[31R] Right Turn Signal
[156] Main to Interconnect Harness
Figure B-54. Inner Fairing Connectors (FLTR)
Appendix B B-35
HOME
FLTR (Continued)
No.
Description
Type
Location
Fig.
[88]
TP Sensor ***
3 - Place Delphi
Below Fuel Tank (Right Side)
-
[89]
IAT Sensor ***
2 - Place Delphi
Below Fuel Tank (Right Side)
-
[90]
ET Sensor ***
2 - Place Delphi
Back of Front Cylinder (Left Side)
-
[91]
Data Link
4 - Place Deutsch
Under Right Side Cover
45
[93]
Tail Lamp
4 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[94]
Rear Fender Lights Harness to Circuit Board
6 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
Instrument Nacelle Switches
[105]
Interconnect to Nacelle Switch Harness [105A, 105B]
12 - Place Multilock
Inside Instrument Nacelle (Under Bezel)
53
Nacelle Switch Harness to Speaker Switch [105C, 105D]
4 - Place Multilock
Inside Instrument Nacelle (Under Bezel)
53
[107]
Ambient Air Temperature Sensor
3 - Place Multilock
Inside Instrument Nacelle (Under Bezel)
53
[108]
Tachometer
12 - Place Packard (Gray)
Inside Instrument Nacelle (Back of Tachometer)
53
[110]
Voltmeter Lamp
Spade Connector
Inner Fairing
-
[111]
Voltmeter
Spade Connector
Inner Fairing
-
[112]
Oil Pressure Gauge Lamp
Spade Connector
Inner Fairing
-
[113]
Oil Pressure Gauge
Spade Connector
Inner Fairing
-
[114]
Air Temperature Gauge Lamp
Spade Connector
Inner Fairing
-
[115]
Air Temperature Gauge
Spade Connector
Inner Fairing
-
[116]
Fuel Gauge Lamp
Spade Connector
Inner Fairing
-
[117]
Fuel Gauge
Spade Connector
Inner Fairing
-
[119]
EFI Fuses ***
Fuse Terminals
Fuse Block (Under Right Side Cover)
45
[121]
Rear Brake Light Switch
Spade Terminals
Beneath Transmission (Right Side)
-
[122]
Horn
Spade Terminals
Between Cylinders (Left Side)
-
[123]
Starter Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
52
[124]
Brake Light Relay
Relay Connector
Fuse Block (Under Left Side Cover)
44
[126]
Ignition Keyswitch Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
52
[128]
Starter Solenoid
Spade Terminals
Top of Starter
-
[129]
Harness Grounds
Ring Terminals
Upper Frame Cross Member (Under Seat)
46
[131]
Neutral Switch
Post Terminals
Transmission Top Cover
-
[132]
Cigarette Lighter
Spade Terminals
Inner Fairing
-
[135]
EFI System Relay ***
Relay Connector
Fuse Block (Under Right Side Cover)
45
[139]
Oil Pressure Sender
4 - Place Delphi
Front Right Crankcase
-
[141]
Fuel Level Sender (and Fuel Pump on EFI models)
4 - Place Packard
Top of Canopy (Under Console)
-
[142]
Security Siren (Optional)
3 - Place Delphi
Under Right Side Cover (Behind Electrical Bracket)
45
[156]
Main to Interconnect Harness
6 - Place Deutsch
Inner Fairing - Below Radio (Right Side)
54
[160]
B+
1 - Place Packard
Upper Frame Cross Member (Under Seat)
46
*** Fuel Injected Models
**** Carbureted Models
B-36
Appendix B
HOME
FLHR/C/S
No.
Description
Type
Location
Fig.
[4]
Accessory
4 - Place Deutsch
Upper Frame Cross Member (Under Seat)
46
[5]
Maxi-Fuse
2 - Place Packard
Under Left Side Cover
43
[7]
Rear Fender Lights Harness
8 - Place Multilock
Top of Rear Fender (Under Seat)
49
[10]
ICM ****
12 - Place Deutsch (Black)
Under Right Side Cover
48
[18]
Left Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[19]
Right Rear Turn Signal
2 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[21]
Indicator Lamps
8 - Place Deutsch
Under Console
56
[22]
Right Handlebar Switches
6 - Place Deutsch
Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Right Side)
55
[24]
Left Handlebar Switches
6 - Place Deutsch
Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Left Side)
55
[30]
TSM/TSSM
12 - Place Deutsch
Cavity at Rear of Battery Box (Under Seat)
52
[31]
Front Turn Signals
6 - Place Multilock
Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Left Side)
55
[32]
Front Fender Tip Lamp Jumper Harness (DOM)
2 - Place Multilock (Black)
Inside Headlamp Nacelle
55
[33]
Ignition/Light Key Switch
3 - Place Packard
Under Console
56
[38]
Headlamp
Headlamp Connector
Inside Headlamp Nacelle
55
[39]
Speedometer
12 - Place Packard
Back of Speedometer (Under Console)
56
[45]
Rear Fender Tip Lamp (DOM)
3 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[46]
Stator
3 - Place Lyall
Bottom of Voltage Regulator (Left Side)
51
[64]
Fuse Block
Packard
Under Left Side Cover
43,44
[65]
VSS
3 - Place Deutsch
Under Right Side Cover (Behind Electrical Bracket)
45
[67]
Accessory Switch
4 - Place Amp
Inside Headlamp Nacelle
55
[73]
Auxiliary Lamps
2 - Place Multilock (White)
Inside Headlamp Nacelle
55
[75]
Cruise Roll-Off Switch **
Spade Contacts
Right Side of Steering Head
-
[77]
Voltage Regulator
2 - Place Lyall
Bottom of Voltage Regulator (Right Side)
51
[78]
ECM ***
36 - Place Packard
Under Right Side Cover
45
FLHR/C/S Continued ...
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 B-55. Headlamp Nacelle Connectors (FLHR/C/S)
Appendix B B-37
HOME
FLHR/C/S (Continued)
No.
Description
Type
Location
Fig.
[79]
CKP Sensor
2 - Place Deutsch
Bottom of Voltage Regulator
51
[80]
MAP Sensor
3 - Place Packard
Top of Intake Manifold/Induction Module
-
[83]
Ignition Coil
4 - Place Delphi
Below Fuel Tank (Left Side)
-
[84]
Front Injector ***
2 - Place Delphi
Below Fuel Tank (Left Side)
-
[85]
Rear Injector ***
2 - Place Delphi
Below Fuel Tank (Left Side)
-
[87]
IAC ***
4 - Place Delphi
Below Fuel Tank (Right Side)
-
[88]
TP Sensor ***
3 - Place Delphi
Below Fuel Tank (Right Side)
-
[89]
IAT Sensor ***
2 - Place Delphi
Below Fuel Tank (Right Side)
-
[90]
ET Sensor ***
2 - Place Delphi
Back of Front Cylinder (Left Side)
-
[91]
Data Link
4 - Place Deutsch
Under Right Side Cover
45
[93]
Tail Lamp
4 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[94]
Rear Fender Lights Harness to Circuit Board
6 - Place Multilock
Circuit Board Under Tail Lamp Assembly
50
[108]
Optional Tachometer
1 - Place Amp
Inside Headlamp Nacelle
-
[109]
Auxiliary Lamps Switch
4 - Place Amp
Inside Headlamp Nacelle
55
[117]
Fuel Gauge
4 - Place Multilock
Below Fuel Tank (Left Side)
-
[119]
EFI Fuses ***
Fuse Terminals
Fuse Block (Under Right Side Cover)
45
[120]
Oil Pressure Switch
Post Terminal
Front Right Crankcase
-
[121]
Rear Brake Light Switch
Spade Terminals
Beneath Transmission
-
[122]
Horn
Spade Terminals
Between Cylinders (Left Side)
-
[123]
Starter Relay
Relay Connector
Fuse Block (Under Left Side Cover)
-
[124]
Brake Light Relay
Relay Connector
Fuse Block (Under Left Side Cover)
44
[126]
Ignition Keyswitch Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
52
[128]
Starter Solenoid
Spade Terminals
Top of Starter
-
[129]
Harness Grounds
Ring Terminals
Upper Frame Cross Member (Under Seat)
46
[131]
Neutral Switch
Post Terminals
Top of Transmission
-
[135]
EFI System Relay ***
Relay Connector
Fuse Block (Under Right Side Cover)
45
[141]
Fuel Level Sender (and Fuel Pump on EFI models)
4 - Place Packard
Top of Canopy (Under Console)
-
[142]
Security Siren (Optional)
3 - Place Delphi
Under Right Side Cover (Behind Electrical Bracket)
45
[143]
Front Fender Tip Lamp (DOM)
2 - Place Multilock (Black)
Under Front Fender Tip Lamp Bracket
-
[158]
Left Handlebar Switches (Cruise Control) **
2 - Place Deutsch (Gray)
Inside Headlamp Nacelle
55
[159]
Right Handlebar Switches (Cruise Control) **
2 - Place Deutsch (Black)
Inside Headlamp Nacelle
55
[160]
B+
1 - Place Packard
Upper Frame Cross Member (Under Seat)
46
** FLHRC Only
*** Fuel Injected Models
**** Carbureted Models
[33]
[39]
[21] Indicator Lights
[33] Ignition/Light Key Switch
[21]
[39] Speedometer Gauge
f2095x8x
Figure B-56. Instrument Console Connectors (FLHR/C)
B-38
Appendix B
HOME
WIRING DIAGRAMS
B.8
SUBJECT
PAGE NO.
FLHX, FLHT, FLHTC, FLHTCU
Main Harness
B-41, B-43
Interconnect Harness
B-45
Tail Lamp, Auxiliary Lamps, Fender Tip Lamps, Directional Lamps
and Tour-Pak Lights
B-47
Starting and Charging
B-49
Handlebar Switches and Indicator Lamps
B-51
Fairing Cap Switches
B-51
Radio, CB/Intercom and Rear Speakers
B-53
XM, Hands Free Phone and Navigation
B-53
FLTR
Main Harness
B-41, B-43
Interconnect Harness
B-45
Tail Lamp and Directional Lamps
B-47
Starting and Charging
B-49
Handlebar Switches and Indicator Lamps
B-51
Instrument Nacelle Switches
B-51
Radio
B-53
FLHR, FLHRC, FLHRS
Main Harness
B-55, B-57
Starting and Charging
B-59
Handlebar Switches, Speedometer, Indicator Lamps, Tail Lamp, Auxiliary Lamps,
Directional Lamps, Fender Tip Lamps and Aux Lamp/Accessory Switches
B-61
TLE Sidecar, TLE Ultra Sidecar
Amplifier
B-63
Sidecar Speakers and Switches
B-63
NOTE
Harness Part No.’s may be included on some wiring diagrams. Use these numbers for reference only.
ALWAYS REFER TO THE PARTS CATALOG WHEN ORDERING WIRING HARNESSES.
Appendix B B-39
HOME
NOTES
B-40
Appendix B
HOME
**CARBURETED ONLY
TSM/TSSM
*EFI
40A
BATTERY
1
BN/GY
KEYSWITCH
IGNITION
2
GY
FUELLEVEL
OPTIONAL
MAXI-FUSE
TO
SERIAL DATA LINK
3
LGN/V
SENDER
SECURITY
IGNITION
IGN RELAY
SECURITY INDICATOR
4
BN/V
SIREN
SWITCH
LEFT TURN FEED
5
V
FUEL
[33A]
RIGHT TURN FEED
6
BN
PUMP
[141A]
VOLTAGE
P&A
[126A]
RIGHT TURN SW INPUT
7
W/BN
REGULATOR
BATTERY
1 2 3
LEFT TURN SW INPUT
8
W/V
9
TN/GN
[142A]
[5B]
[33B]
START RELAY CONTROL
FUELPUMP
A B C
D
A B
1 2
IGNITION ENABLE
10
ASSEMBLY INTANK
ALARM SIGNAL
11
LGN/BN
GROUND
12
BK
AT TOP OF TANK
A B C
D
1
2 3
[77B]
[160B]
[126B]
MAIN POWER
[30A]
[30B]
TURN SIGNAL/
[141B]
[142B]
AT STARTER
TURN SIGNAL SECURITY
(GY)
70369-06
MODULE
FUELTANK
[13B]
BK
HARNESS
1 2 3
4
[141A]
LGN/V
1 2 3
4
*O/GY
A B C
D
*R
[13A]
BK
R
GY
W/GN
*PK **BE/O
[64B]
W/BK
**BN/GY
O/V
4E
5
CLEAN GROUND
87
[8B]
BK/GN
RH GND
BK
R/Y
3F
30 3
BRAKE
STUD
R/BE
3E
85 2
RELAY
- FRAME GROUND -
BK
4F
86 1
12
GN/R
11
BK
LH GND
BK
R/BE
10
W/V
STUD
1B
INSTRUMENTS - 15A
1A
TO
9
W/BN
DIRTY GROUND
O
R/BK
O/BE
INTERCONNECT
8
BN
1D
LIGHTS - 15A
1C
HARNESS
7
V
BE
6
W/BK
1H
HEADLAMP - 15A
1G
[1A]
5
O/W
BE
START RELAY
(BK)
4
O/R
1F
IGNITION - 15A
1E
3
GY
GY
R/BK
2
O/V
GY
4D
P&A IGN - 2A MAX
4C
1
O
R/BK
[123A]
2B
CRUISE/BRAKE - 15A
2A
[1B]
O/V
2D
ACCESSORIES - 15A
2C
O/W
12
BK
O/W
[123B]
11
2F
P&A - 15A
2E
10
TN
O/R
R/GY
TO
9
3B
RADIO MEM - 15A
3A
INTERCONNECT
GN/Y
R/O
R
8
BN/GN
3D
BATTERY - 15A
3C
HARNESS
7
O
[2A]
6
Y/BK
BN/GY
(GY)
5
Y/W
RADIO PWR - 15A
4
BN/GY
O/BE
4B
4A
O/GN
3
BE
2
BK/R
1
R/BE
[2B]
[128B]
TO
D
BK
INTERCONNECT
C
BK/GN
HARNESS
B
BE
START
[15A]
A
R/O
SOLENOID
[15B]
CRANK POSITION
BK
4
SENSOR
O
3
ACCESSORY
R/Y
2
CONNECTOR
O/R
1
(BK)
BK
2
2
[12B]
[4A]
R
1
1
BK
321
(BK - LOCATED UNDER SEAT)
[79A]
[79B]
NEUTRAL
SWITCH
TOUR-PAK
BN/GN
[12A]
GN/Y
THROTTLE
[131]
[17B]
ROLL-OFF
[75C]
HORN
[139B]
SWITCH
D C B A
[7A]
REAR
[156A]
[17A]
OIL
[75A]
STOPLIGHT
1 2 3 4 5 6 7 8
PRESSURE
[75D]
SWITCH
TO REAR
SENDER
O/V
6 5
4
3
2
1
*EFI ONLY
[139A]
V./Y
[122 ]
[121]
LIGHTING
[75B]
TO INTERCONNECT
[7B]
[156B]
**CARBURETED ONLY
(GY)
f2428a8x
CRUISE CONTROL MODULE
2006 FLHX, FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,
Main Harness (Page 1 of 2)
B-41
HOME
2006 FLHX, FLHT, FLHTC, FLHTCU and FLTR
2006 FLHX, FLHT, FLHTC, FLHTCU and FLTR
DOMESTIC and INTERNATIONAL Models,
DOMESTIC and INTERNATIONAL Models,
Main Harness (Page 1 of 2)
Main Harness (Page 1 of 2)
B-42
Appendix B
HOME
MAP
DATA
IGNITION
SENSOR
3
2
1
LINK
COIL
+5V DC
**CARBURETED
(GY)
1234
3
2
1
R/W
A
A
R
IGNITION
W/GN
B
B
W
COIL
VEHICLES
[91A]
[83B]
[80A]
BK
C
C
BK
[83A]
(CARB)
OUTPUT
[65B]
SENSOR
GROUND
CB A
(BK)
[65A]
VEHICLE
IGNITION CONTROL MODULE
[80B]
SPEED SENSOR
(BLK)
[BLK]
[10A]
[10B]
BK
[83A]
RUN/STOP SIGNAL
1
1
W/BK
LGN/V
ABCD
BATTERY
2
2
BN/GY
IGNITION
+5V SENSOR PWR
3
R/W
FRONT SPARK
REAR SPARK
3
PLUG
COIL
SENSOR GROUND
4
4
BK/W
BK
PLUG
(EFI)
MODULE GROUND
5
5
BK
R
COIL FRONT
6
6
BE/O
GY
COIL REAR
7
7
Y/BE
W/GN
CRANK SENSOR (+)
8
8
R
CRANK SENSOR (-)
9
9
BK
BE/O
VEHICLE SPD SIG
10
10
W/GN
W/BK
MAP SIGNAL
11
V/W
BN/GY
11
12
+5V DC
DATALINK
12
LGN/V
R/W
A
A
R
W/GN
B
B
W
BK
C
C
BK
OUTPUT
[65B]
SENSOR
(BK)
[65A]
GROUND
VEHICLE
SPEED SENSOR
INTAKE
REAR
FRONT
ENGINE
AIR
INJECTOR
INJECTOR
IDLE AIR
TEMP.
TEMP.
THROTTLE
CONTROL
*ELECTRONIC
SENSOR
SENSOR
POSITION
MAP
BK
LGN/V
FUEL INJECTED
SENSOR
SENSOR
O/GY
VEHICLES
R
DATA
IGNITION
BK
LINK
COIL
R
GY
1234
AB
12
ABCD
W/GN
[91A]
ELECTRONIC
[83B]
DCB A
PK
(GY)
[89B]
AB
AB
3
2
1
CBA
[87B]
W/BK
CONTROL
[90B]
[85B]
[84B]
[88B]
[80B]
MODULE
[78A]
[78B]
N/C
N/C
TACH OUTPUT
PK
SYSTEM RELAY
GN/O
SERIAL DATA LINK
LGN/V
ENGINE TEMPERATURE
PK/Y
INTAKE AIR TEMPERATURE
LGN/Y
N/C
N/C
POWER GROUND
BK
COIL REAR
Y/BE
[119B]
CRANK POS. SENSOR (-)
BK
SWITCH POWER
W/BK
FUEL PUMP 15A
5V SENSOR POWER
R/W
G
H
N/C
O/GY
Y/GN
N/C
IDLE AIR CONTROL MOTOR
BK/O
ECM POWER 15A
IDLE AIR CONTROL MOTOR
BK/PK
A
B
INJECTOR REAR
GN/GY
R
N/C
BE/GY
INJECTOR FRONT
W/Y
(BK)
SYSTEM RELAY
N/C
N/C
Y/GN
K
87
5
THROTTLE POS. SNSR INPUT
GY/V
T
87A
4
MAP SENSOR INPUT
V/W
BE/GY
E
30
3
5V SENSOR GROUND
BK/W
GN/O
S
85
2
ION SENSE
GY/BE
W/BK
U
1
POWER GROUND
BK
86
COIL FRONT
BE/O
CRANK POS. SENSOR (+)
R
CONSTANT POWER
BE/GY
N/C
VEHICLE SPEED INPUT
W/GN
N/C
IDLE AIR CONTROL MOTOR
BE/GN
IDLE AIR CONTROL MOTOR
BN/R
f2428c8x
2006 FLHX, FLHT, FLHTC, FLHTCU and FLTR, DOMESTIC and INTERNATIONAL Models,
Main Harness (Page 2 of 2)
B-43