Harley Davidson 2011 Touring Models. Service Manual - page 27

Secure chaser wires to terminals. Carefully draw terminals
back through conduit.

Remove chaser wires.

Install terminals into connector housing. Refer to

Table 7-9

Table 7-10

. See

7.11 HEADLAMP: ALL EXCEPT ROAD GLIDE

See

Figure 7-46

. Start two screws to secure turn signal

lamp to mounting bracket. Verify that conduit fits in slot at
back of bracket and is not pinched. Tighten screws to
30-60

in-lbs

(4.1-6.8 Nm).

Connect front turn signal/auxiliary lamp connector.

Road King models:

See

Figure 7-47

. Secure anchor to

fork stem nut lockplate. Install headlamp assembly. See

Fork mounted fairing models:

See

2.34 UPPER

FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING
MODELS

. Secure connector on T-stud at top of fairing

support brace. Verify that conduit is routed inboard using
relief in upper outboard corner of chrome skirt. Install outer
fairing.

WINDSHIELD: FORK MOUNTED FAIRING MODELS

7-40 2011 Touring Service: Electrical

sm03621

Figure 7-49. Fix Mechanics Wire to Socket Terminal

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

10. Test lamp operation.

Removal: Bullet Style, Fork Mounted

Remove outer fairing. See

2.34 UPPER FAIRING AND

See

Figure 7-48

. Disconnect the turn signal lamp con-

nector [31L/R], 4-place Multilock.

See

Figure 7-50

. Remove two screws to release turn signal

lamp mounting bracket from upper and lower fork brackets.

To remove reflector/isolator assembly, proceed as follows:

Remove terminals from connector housing. See

A.19 TYCO 070 MULTILOCK UNSEALED CON-
NECTOR

Pull mounting bracket from conduit.

Remove lens and bulb.

See

Figure 7-52

. Insert a right angle pick or a 7/64

in. hex key through hole (4) and pull reflector from
lamp.

Remove isolator (3) from lamp if still installed.

sm03650

Figure 7-50. Front Turn Signal Lamp (FLHX)

sm03651

Figure 7-51. Route Conduit Through Mounting Bracket and

Chrome Skirt Reliefs (FLHX)

2011 Touring Service: Electrical 7-41

sm06184

1. Lamp terminal base
2. Spring
3. Isolator
4. Hole

Figure 7-52. Reflector/Isolator Assembly

Installation: Bullet Style, Fork Mounted

To install reflector/isolator assembly, proceed as follows:

Seat reflector assembly in rubber isolator, aligning
tab on reflector with slot in isolator.

Feed wires through lens opening and out through
unthreaded hole.

Aligning tab on reflector with slot inside lamp, use
thumbs of both hands and apply even pressure
around outer edge of reflector assembly until fully
seated.

Liberally apply dielectric grease to contacts in socket
and at bottom of bulb. Install bulb and lens with slot
at bottom of lamp.

Feed wires through hole in mounting bracket.

Install lamp on mounting bracket and tighten screw
to 15-20 ft-lbs (20-27 Nm).

Install terminals into connector housing as shown in

Table 7-11

. See

WINDSHIELD: FORK MOUNTED FAIRING MODELS

Table 7-11. Turn Signal Lamp Connector (Bullet Style)

RIGHT SIDE [31R]

LEFT SIDE [31L]

CHAMBER

WIRE COLOR

CHAMBER

WIRE COLOR

Blue

Brown

Violet

Black

Empty

Start two screws to fasten turn signal lamp mounting
bracket to upper and lower fork brackets.

See

Figure 7-51

. Verify that conduit is routed as shown

and tighten screws to 15-20 ft-lbs (20-27 Nm).

See

Figure 7-48

. Connect front turn signal lamp connector

and secure to fairing support brace.

Install outer fairing. See

2.34 UPPER FAIRING AND

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Test lamp operation.

Removal: Bullet Style, Fairing Mounted

Remove outer fairing and front turn signal lamp. See

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS

To remove reflector/isolator assembly, proceed as follows:

Remove terminals from connector housing. See

A.19 TYCO 070 MULTILOCK UNSEALED CON-
NECTOR

Pull lamp from mounting bracket.

Remove lens and bulb.

See

Figure 7-52

. Insert a right angle pick or a 7/64

in. hex key through hole (4) and pull reflector from
lamp.

Remove isolator (3) from lamp if still installed.

7-42 2011 Touring Service: Electrical

Installation: Bullet Style, Fairing Mounted

Assemble front turn signal lamp as follows:

Seat reflector assembly in rubber isolator, aligning
tab on reflector with slot in isolator.

Feed wires through lens opening and out through
unthreaded hole.

Aligning tab on reflector with slot inside lamp, use
thumbs of both hands and apply even pressure
around outer edge of reflector assembly until fully
seated.

Liberally apply dielectric grease to contacts in socket
and at bottom of bulb. Install bulb and lens with slot
at bottom of lamp.

Install lamp onto mounting bracket.

Install terminals into connector housing as shown in

Table 7-11

. See

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS

Install outer fairing and front turn signal lamps. See

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Test lamp operation.

REAR TURN SIGNAL LAMP

Removal: FLHR/C, FLHTC/U, FLHTK

Remove saddlebag as necessary. See

2.26 SADDLE-

BAGS

Remove two screws to release tail lamp assembly from
chrome base.

sm03653

1. Left turn signal lamp [18]
2. Right turn signal lamp [19]
3. Tail lamp [93]

Figure 7-53. Release Tail Lamp Connector

sm03655

1. Opening
2. Fender hole

Figure 7-54. Release Turn Signal Lamp Connector

See

Figure 7-53

. Disconnect tail lamp connector [93] (3),

(4-place Multilock). Set tail lamp assembly aside.

See

Figure 7-54

. Disconnect turn signal lamp assembly,

(2-place Multilock). For best results, use a pick or small
screwdriver to press release button.

Feed connector housing through opening (1) in chrome
base to inboard side of rear fender.

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

2011 Touring Service: Electrical 7-43

Release harness from cable clip inside fender.

Draw harness and connector housing out through fender
hole (2).

Draw connector housing through channel on inboard side
of rear turn signal lamp bracket, so that length of conduit
hangs below turn signal lamp.

Inserting a long shank ball end socket (Snap-On FABL5)
through channel in bracket, remove two screws to release
turn signal lamp assembly.

10. Remove

terminals

from

connector

housing.

See

Installation: FLHR/C, FLHTC/U, FLHTK

Place

new

turn signal lamp assembly next to discarded

unit and cut wires to proper length.

Crimp

new

terminals onto turn signal lamp wires. See

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

Install terminals into connector housing. Refer to

Table 7-12

. See

A.19 TYCO 070 MULTILOCK UNSEALED

CONNECTOR

Table 7-12. Rear Turn Signal Lamps Connector (models

with tail lamp)

CAVITY NUMBER

WIRE COLOR

Violet

Black

Install turn signal lamp assembly and tighten screws to
30-50

in-lbs

(3.4-5.6 Nm).

See

Figure 7-54

. Route connector housing through

channel in bracket, then feed through fender hole (2).

Capture harness in cable clip under fender.

Feed connector housing through opening (1) in chrome
base.

See

Figure 7-53

. Connect turn signal harness connector

(1 or 2) to pin housing/circuit board.

Connect 4-place Multilock tail lamp connector (3). Verify
that tail lamp conduit is positioned outboard of the rear
fender tip lamp and left turn signal lamp harnesses.

NOTE

Over tightening screws can crack the lens.

10. Install tail lamp and tighten screws to 20-24

in-lbs

(2.3-

2.7 Nm).

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

11. Test lamp for proper operation.

12. Install saddlebag.

Removal: FLHX, FLTRX, FLTRU

NOTES

•

This procedure covers replacement of the rear turn signal
lamp reflector/ isolator assembly only.

•

LED-type lamps can not be replaced individually. The
entire bracket must be replaced as an assembly. See

7.16 TURN SIGNAL LAMPS, Rear Turn Signal Lamps
Bracket

Models with tail lamp:

Remove chrome base and circuit board assembly.
See

SIGNAL LAMPS, Rear Turn Signal Lamps Bracket

Remove terminals from turn signal lamp connector
housing.

See

Release harness from cable clip inside fender.

Draw harness and terminals through hole to outboard
side of fender. Proceed with reflector/isolator removal.

Models without tail lamp:

Remove turn signal lamps bracket. See

7.16 TURN

Remove grommet from harness.

Remove license plate bracket.

Remove screws securing license plate lamp.

Remove terminals from connector housing. See

A.9 DELPHI MICRO 64 SEALED CONNECTORS

Pull wires through main conduit. Proceed with
reflector/isolator removal.

Reflector/isolator removal:

Remove lens and bulb.

Push grommet into lamp housing. Lightly lubricate
grommet with glass cleaner, if necessary.

See

Figure 7-55

. Insert a right angle pick or a 7/64

in. hex key through hole (4) and pull reflector from
lamp.

Remove rubber isolator (3) from lamp if still installed.

Installation: FLHX, FLTRX, FLTRU

Place

new

reflector/isolator assembly next to discarded

unit and cut wires to proper length.

MULTILOCK UNSEALED CONNECTOR

7-44 2011 Touring Service: Electrical

Install reflector/isolator assembly:

Seat reflector assembly in rubber isolator, aligning
tab on reflector with slot in isolator.

Feed wires through lens opening and out through hole
in lamp housing.

Install grommet in lamp housing. Lightly lubricate
grommet with glass cleaner, if necessary.

Aligning tab on reflector with slot inside lamp, use
thumbs of both hands and apply even pressure
around outer edge of reflector assembly until fully
seated.

Liberally apply dielectric grease to contacts in socket
and at bottom of bulb. Install bulb and lens with slot
at bottom of lamp.

Models with tail lamp:

Install

new

terminals onto wires. See

A.19 TYCO 070

Feed terminals through hole to inboard side of fender.

Install terminals into connector housing. Refer to

Table 7-12

. See

Capture harness in cable clip inside fender.

Install chrome base and circuit board assembly. See

LAMPS, Rear Turn Signal Lamps Bracket

Models without tail lamp:

Feed wires through main conduit. Install

new

ter-

minals and install in connector housing. Refer to

. See

Route both turn signal lamp harnesses under license
plate lamp area and install license plate lamp and
license plate bracket. See

7.16 TURN SIGNAL

Install turn signal lamps bracket. See

7.16 TURN

SIGNAL LAMPS, Rear Turn Signal Lamps Bracket

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Test lamp operation.

Table 7-13. Rear Turn Signal Lamps Connector

(Incandesent) (models without tail lamp)

FUNCTION

CAVITY

NUMBER

WIRE COLOR

Right turn

Violet/Brown

Left turn

Violet

Plug

Left ground

Black

Right ground

Black

License plate lamp

Black

Left tail

Blue

Right tail

Blue

Plug

License plate lamp ground

Black

Plug

Table 7-14. Rear Turn Signal Lamps Connector (LED)

(models without tail lamp)

FUNCTION

CAVITY

NUMBER

WIRE COLOR

Right turn

Green/stripe

Right tail

White/stripe

Right stop

Red/stripe

Right ground

Yellow/stripe

License plate lamp ground

Black

Plug

Left turn

Green

Left tail

White

Left stop

Red

License plate lamp

Black

Left ground

Yellow

Plug

2011 Touring Service: Electrical 7-45

sm06184

1. Lamp terminal base
2. Spring
3. Isolator
4. Hole

Figure 7-55. Reflector/Isolator Assembly

REAR TURN SIGNAL LAMPS BRACKET

Removal: FLHR/C, FLHTC/U, FLHTK

Remove chrome base and circuit board assembly. See

7.16 TURN SIGNAL LAMPS, Rear Turn Signal Lamp

Remove rear turn signal lamps from bracket. See

this section.

If equipped with license plate lamp on turn signal bracket,
remove terminals from license plate lamp connector. See

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

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

If equipped with license plate lamp on turn signal bracket,
remove license plate bracket and lamp.

Installation: FLHR/C, FLHTC/U, FLHTK

If equipped with license plate lamp on turn signal bracket,
install license plate lamp and bracket. Tighten license plate
bracket screws to 60-80

in-lbs

(6.8-9.0 Nm).

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

Install rear turn signal lamps bracket and tighten screws
to 84-144

in-lbs

(9.5-16.3 Nm).

If equipped with license plate lamp on turn signal bracket,
route wires through hole in fender and install terminals
into license plate lamp connector. See

A.19 TYCO 070

MULTILOCK UNSEALED CONNECTOR

. Also refer to

Table 7-15

Install rear turn signal lamps in bracket. See

7.16 TURN

SIGNAL LAMPS, Rear Turn Signal Lamp

in this section.

Install chrome base and circuit board assembly. See

Removal: FLHX, FLTRX, FLTRU

Models with tail lamp:

Remove circuit board and chrome base. See

A.19 TYCO 070 MULTILOCK UNSEALED

See

Figure 7-56

. Release turn signal lamp harnesses

(4) from cable clips.

Remove terminals from license plate lamp connector.
See

CONNECTOR

Models without tail lamp:

See

Figure 7-57

. Disconnect turn signal connector

(3) from rear fascia lamp.

Release harness from J-clamp (2) located above
fascia lamp.

Push grommet (1) rearward out of hole in fender.

Remove two screws to release rear turn signal lamps
bracket. Remove bracket and harnesses

Remove screws to release license plate bracket and lamp
from turn signal bracket.

sm06624

1. P-clamp
2. Jumper harness
3. Clamp, tee-stud
4. Turn signal lamps harnesses

Figure 7-56. Tail Lamp Jumper Harness (models with tail

lamp)

A.19 TYCO 070 MULTILOCK UNSEALED

7-46 2011 Touring Service: Electrical

sm06606a

1. Grommet
2. J-clamp
3. Connector

Figure 7-57. Rear Turn Signal Lights Connector (models

without tail lamp)

sm06724

1. Grommet
2. License plate bracket screws

Figure 7-58. Rear Turn Signal Lamps and Harness (models

without tail lamp)

Installation: FLHX, FLTRX, FLTRU

Install license plate lamp and bracket onto turn signal
bracket. Tighten screws to 60-80

in-lbs

(6.8-9.0 Nm).

Models with tail lamp:

Feed socket housings of left and

right rear turn signal lamps and license plate wire terminals
through respective holes to inboard side of fender.

Models without tail lamp:

See

Figure 7-58

. Install grommet (1) and orient as

shown.

Route harness through hole in fender and seat
grommet in hole.

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

Install rear turn signal lamps bracket and tighten screws
to 84-144

in-lbs

(9.5-16.3 Nm).

Models with tail lamp:

Install terminals into license plate lamp connector.
See

CONNECTOR

. Also refer to

Table 7-15

Install chrome base and circuit board assembly. See

Models without tail lamp:

See

Figure 7-57

. Install connector (3).

Secure harness in J-clamp (2) and under tab on end
of fascia lamp.

Table 7-15. License Plate Lamp Connector [45]

CHAMBER NUMBER

WIRE COLOR

Black

Not Used

Black

2011 Touring Service: Electrical 7-47

7.17

IGNITION/LIGHT KEY SWITCH AND FORK LOCK

FAIRING MODELS

TOOL NAME

PART NUMBER

IGNITION SWITCH CONNECTOR
REMOVER

HD-45961

IGNITION SWITCH ALIGNMENT TOOL

HD-45962

Removal

Remove main fuse. See

7.7 SYSTEM FUSES AND

RELAYS

Remove the ignition switch knob:

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

See

Figure 7-59

. Turn the front forks to the left fork

stop and rotate the knob to FORK LOCK.

Press and hold the release button at bottom (left side)
of the knob, and turn key 60 degrees counterclock-
wise.

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

NOTE

See

Figure 7-61

. After removal of the knob, the IGNITION

SWITCH ALIGNMENT TOOL (Part No. HD-45962) may be
used to move the switch to other positions as required. Insert
tool until bottom of handle contacts top of threaded post, and
then rotate handle to the selected position.

60°

sm03678a

Figure 7-59. Ignition Switch Knob Release Button (Top and

Bottom Views)

sm03679

Figure 7-60. Ignition Switch Alignment Tool

sm03680

Figure 7-61. Bottom Alignment Tool in Threaded Post and

Rotate to Desired Position

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

Remove collar and spacer from threaded post.

Remove the switch position plate by pulling tabs from slots
in fairing cap or instrument nacelle (depending on model).

AND WINDSHIELD: FORK MOUNTED FAIRING
MODELS

7-48 2011 Touring Service: Electrical

Fork mounted fairing models:

Remove outer fairing. See

2.34 UPPER FAIRING

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

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

Remove fairing cap. See

2.35 FAIRING CAP: FORK

2.40 INSTRUMENT NACELLE: FRAME

Frame mounted fairing models:

Remove instrument

nacelle. See

Disconnect ignition switch connector [33] as follows:

See

Figure 7-62

. Obtain the IGNITION SWITCH

CONNECTOR REMOVER (Part No. HD-45961).

Gently insert end of

Figure 7-62

into slot in ignition

switch housing until it stops.

See

Figure 7-63

. Pull the main harness and tool at

the same time to release connector from ignition
switch.

sm03681

Figure 7-62. Ignition Switch Connector Remover

sm03682

Figure 7-63. Pull Main Harness Conduit and Tool to Release

Socket Housing

sm03683

1. Knob
2. Spring
3. Nut
4. Collar
5. Spacer
6. Break-away screw (international only)
7. Flat washer
8. Switch housing

Figure 7-64. Ignition Switch Assembly (International)

10.

Domestic:

Remove two screws (with flat washers) at base

of ignition switch housing.

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

11.

International models:

Remove two break-away screws

(with flat washers) as follows.

Use a center punch to make a pilot hole at the top of
each break-away screw.

Install a 1/8 inch left handed bit in drill and set the drill
to REVERSE. Positioning the bit in the pilot hole, spin
out the break-away screws.

2.23 HANDLEBARS, Installation

2011 Touring Service: Electrical 7-49

sm03684

Figure 7-65. Rotate Alignment Tool Without Bottoming

NOTE

If the above method fails, use a 3/16 inch bit with long shank
to carefully drill off heads of break-away screws. Use pliers to
remove the shafts from the upper fork bracket.

12. See

Figure 7-64

. Remove ignition switch housing from

bore of upper fork bracket.

Installation

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

Domestic models:

Install two screws (with flat washers)

at base of ignition switch housing and tighten to 36-60

in-

lbs

(4.1-6.8 Nm).

International:

Install two

new

break-away screws (with

flat washers) as follows.

Verify that the threads in the upper fork bracket are
clean and in good condition. Dirty and/or damaged
threads may cause the heads of the break-away
screws to snap off before the switch housing is prop-
erly tightened.

NOTE

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

Install screws and tighten until heads snap off.

Install handlebars. See

Install ignition switch connector to ignition switch housing.

Install anchor of

new

cable strap in hole at bottom right

side of radio and capture main harness.

Fork mounted fairing models:

Install fairing cap. See

2.35 FAIRING CAP: FORK

WINDSHIELD: FORK MOUNTED FAIRING MODELS

Install four socket head screws to fasten radio or
storage box to left and right radio support brackets.
Tighten screws to 35-45

in-lbs

(4.0-5.1 Nm).

Install outer fairing. See

2.34 UPPER FAIRING AND

Frame mounted fairing models:

Install instrument

nacelle. See

2.40 INSTRUMENT NACELLE: FRAME

Install switch position plate. Plate snaps in place when
properly installed. Exercise care to avoid breaking tabs.
Replace plate if tabs are damaged.

10. See

Figure 7-64

. Install spacer (5) and orient so the widest

side is forward and the inside tabs fit in slots of switch
post.

11. Slide collar (4) over threaded post and orient collar so the

outside tab is forward and the inside tabs fit in slots of
post.

12. Install nut (3). Turn the front forks to the right fork stop,

and using a 7/8 inch Open End Crow Foot, tighten nut to
85-115

in-lbs

(9.6-13.0 Nm).

13. Install spring into bore at underside of knob.

14. Install ignition switch knob:

See

Figure 7-59

. Verify that button at bottom of knob

is pressed and key is turned 60 degrees counterclock-
wise of the UNLOCK position.

With the knob pointing toward the FORK LOCK posi-
tion, insert shaft into threaded post.

Hold the knob down and the turn key clockwise to the
UNLOCK position. An audible "click" should be heard
when knob and switch are properly engaged.

Release the knob and rotate through all four switch
positions to verify proper operation. If the knob does
not install properly, proceed to next step.

15. Knob was removed in the ACCESS position or switch may

have been moved out of the FORK LOCK position. Pro-
ceed as follows:

See

Figure 7-61

. Insert alignment tool until bottom of

handle contacts top of threaded post, and holding
front forks at the left fork stop, rotate handle of tool
counterclockwise until fork locks.

Remove tool and repeat previous step.

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

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

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

7.7 SYSTEM FUSES AND RELAYS

7-50 2011 Touring Service: Electrical

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

Insert shaft into threaded post and gently rotate knob
until it drops into the partially installed position. Take
note whether it is pointing toward the rear, or to
ACCESS, IGNITION or OFF.

See

Figure 7-65

. Remove knob and insert alignment

tool so that the bottom of the handle is approximately
0.500-0.0750 in. (12.7-19.1 mm) from the top of the
threaded post, and then hold.

Rotate alignment tool counterclockwise the number
of positions needed to get to FORK LOCK. Repeat
installation step.

17. Install main fuse. See

ROAD KING MODELS

Ignition/Light Key Switch: Removal

Remove main fuse. See

7.7 SYSTEM FUSES AND

RELAYS

Remove seat. See

2.25 SEAT

Remove console from fuel tank. Lay a clean shop towel
on forward part of rear fender and lay console on shop
towel.

See

Figure 7-66

. Disconnect ignition switch connector

[33]. Release ignition switch conduit from plastic clip, if
necessary.

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

Ignition/Light Key Switch: Installation

See

Figure 7-66

. Install ignition switch and tighten to 20-30

in-lbs

(2.3-3.4 Nm) in a crosswise pattern.

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

Exercising caution to avoid pinching wire harness and vent
tube, install console on fuel tank. Tighten screws to 36-60

in-lbs

(4.1-6.8 Nm).

sm03685

1. Ignition switch connector [33]
2. Screw (4)
3. Plastic clip

Figure 7-66. Instrument Console (Road King)

Install seat. See

2.25 SEAT

Install main fuse. See

7.7 SYSTEM FUSES AND RELAYS

Fork Lock: Removal

Remove handlebar clamp shroud. See

2.44 HEADLAMP

NACELLE: ROAD KING MODELS

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

See

Figure 7-67

. Remove two screws (with flat washers)

and pull fork lock assembly from upper fork bracket bore.

NOTE

On HDI models, use a center punch to make a pilot hole at the
top of each break-away screw. Install a 1/8 inch left handed
bit in drill and set the drill to reverse. Positioning the bit in the
pilot hole, spin out the break-away screws.

Fork Lock: Installation

See

Figure 7-67

. Install

new

fork lock assembly into bore

of upper fork bracket.

Install two screws (with flat washers) and tighten to 36-60

in-lbs

(4.1-6.8 Nm).

NACELLE: ROAD KING MODELS

2011 Touring Service: Electrical 7-51

sm03686

Figure 7-67. Fork Lock (Road King)

NOTE

On HDI models, install new break-away screws and tighten
until heads snap off. Verify that threads in upper fork bracket
are clean and in good condition or heads may break off before
fork lock assembly is properly tightened. Avoid losing heads
of screws in motorcycle as vibration may cause captured heads
to scratch finished surfaces, chafe wires or cause other
damage.

Install handlebar clamp shroud. See

2.44 HEADLAMP

7.17 IGNITION/LIGHT KEY SWITCH AND

7-52 2011 Touring Service: Electrical

7.18

FAIRING CAP SWITCHES: FORK MOUNTED
FAIRING MODELS

REMOVAL

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

FORK LOCK

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

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

See

Figure 7-68

. Remove fairing cap from motorcycle.

Bend back the flexible clamp to release switch wires from
the inboard side of the fairing cap. Carefully cut cable
straps to free wires from bundles.

Remove two screws to release switch bracket from fairing
cap.

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

Figure 7-69

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

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

Figure 7-70

and refer to

Table 7-16

for the applic-

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

10. Remove the appropriate terminals from the socket housing.

NOTE

For instructions on properly removing wire terminals, see

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

sm03687

Auxiliary lamp switch

Fairing cap switch connector [105]

Cable strap

Speaker switch

Cruise switch

Flexible clamp

Switch bracket screws

Accessory switch

10.

Grommet

Switch bracket

Figure 7-68. Fairing Cap (Inboard Side) (typical)

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

2011 Touring Service: Electrical 7-53

INSTALLATION

Feeding wires through bracket, place

new

switch into

position. Engage tabs on switch in slots of latches and
then gently bend tabs upward to lock position of switch in
bracket.

Install terminals into socket housing.

NOTE

For instructions on properly installing wire terminals, see

If Cruise or Speaker Switch was replaced, butt splice
Black/Green wire lead between Cruise and Speaker Switch
terminals.

NOTE

For detailed butt splicing information, see

A.20 SEALED

SPLICE CONNECTORS

Install two screws to secure switch bracket to fairing cap.

Install

new

cable straps to capture wire bundles and then

secure switch wires to the fairing cap using the flexible
clamp. Route the wires as shown in

Figure 7-68

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

sm03688

1. Switch bracket
2. Latch
3. Tab

Figure 7-69. Bend Latches Outward to Release Tabs

Table 7-16. Fairing Cap Switches [105]

CHAMBER

NUMBER

WIRE COLOR

SWITCH

Orange/Red

Accessory

Orange

Black

Orange/Violet

Cruise

Ultra Only

Red/Green

To Speaker Switch

Black/Green

(Double Lugged)

Yellow

Auxiliary Lamp

Gray/Black

Black

Orange/Blue

Speaker

Ultra Only

Violet/Orange

Brown/Orange

To Cruise Switch

Black/Green

5 5

– AMP

sm03689

Figure 7-70. Socket Housing (Secondary Locks Open)

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

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

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

in-lbs

(2.8-3.4 Nm).

10. Assemble ignition switch: install switch position plate,

spacer, collar, nut, spring and knob. See

7.17 IGNI-

TION/LIGHT KEY SWITCH AND FORK LOCK

7.17 IGNITION/LIGHT KEY SWITCH AND

7-54 2011 Touring Service: Electrical

7.19

INSTRUMENT NACELLE SWITCHES: FRAME
MOUNTED FAIRING MODELS

REMOVAL

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

FORK LOCK

Remove screw on each side of bezel.

Use thumbs to push tab at rear of bezel from slot in front
of ignition switch. Gently raise free side of bezel until tabs
at front of instrument nacelle become disengaged from
slot at front of bezel (concealed behind decorative
adhesive strip).

See

Figure 7-71

. Raising bezel slightly, disconnect

instruments and indicator lights from interconnect harness
as follows:

Speedometer connector [39], 12-place Packard.

Tachometer connector [108], 12-place Packard.

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

Remove bezel from motorcycle.

Follow instructions based on location of defective switch.

Left Side Switch

See

Figure 7-71

. Disconnect speaker switch connector

[105], 4-place Multilock.

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

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

See

Figure 7-71

. Unthread rubber boot from odometer

reset switch, and while carefully removing left side instru-
ment nacelle from motorcycle, pull odometer reset switch
from hole. Move left side of nacelle to bench area leaving
right side on motorcycle.

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

See

Figure 7-72

. Carefully pry two latches on bracket

outward to release tabs on switch. Remove switch from
bracket.

sm02877

Speaker switch [105C/D]

Indicator lights [21]

Speedometer gauge [39]

Tachometer gauge [108]

Clutch cable

Instrument nacelle switches [105A/B]

Figure 7-71. Frame Mounted Fairing Models: Instrument Nacelle (Bezel Removed)