Harley Davidson 2011 Touring Models. Service Manual - page 28

Right Side Switches

See

. Disconnect speaker switch connector

[105], 4-place Multilock.

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

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

See

Figure 7-73

. Remove the appropriate terminals from

the socket and/or pin housings. Follow the wires of the
faulty switch or reference

Table 7-17

for the applicable

chamber numbers. For wire location purposes, numbers
are stamped into the secondary locks.

NOTE

For instructions on properly removing wire terminals, see

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

Carefully pull wires to draw terminals through conduit to
backside of switch. For best results, pull one wire at a
time.

sm03688

1. Switch bracket
2. Latch
3. Tab

Figure 7-72. Bend Latches Outward to Release Tabs

Table 7-17. Right Side Instrument Nacelle Switches

CHAMBER NUMBER

WIRE COLOR

SWITCH

4-PLACE

PIN

12-PLACE

SOCKET

Orange/Red

Accessory

Orange

Black

Orange/Violet

Cruise

Red/Green

Black/Green

(Double

Lugged)

5 5

– AMP

sm03689

Figure 7-73. Socket Housing (Secondary Locks Open)

INSTALLATION

Left Side Switch

Place

new

switch into position in bracket. Engaging tabs

on switch in slots of latches, gently bend tabs upward to
lock position of switch in bracket.

Snap switch bracket into molded retainer in instrument
nacelle.

See

Figure 7-74

. While carefully placing left side of

instrument nacelle on motorcycle, slide odometer reset
switch through hole and install rubber boot.

See

Figure 7-71

. Connect speaker switch connector [105],

4-place Multilock.

Install two screws (with flat washers) to fasten left side
instrument nacelle to upper and lower fork brackets.
Alternately tighten screws to 15-20 ft-lbs (20-27 Nm).

Capture clutch cable in cable clip. Insert cable clip into
hole in left side of instrument nacelle.

Right Side Switches

See

Figure 7-72

. Place

new

switch into position in bracket.

Engaging tabs on switch in slots of latches, gently bend
tabs upward to lock position of switch in bracket.

HOME

7-56 2011 Touring Service: Electrical

sm03585

Right side nacelle

Left side nacelle

Clutch cable clip hole

Speaker switch connector [105C]

Instrument nacelle switch connector [105B]

Speaker switch connector [105D]

Figure 7-74. Instrument Nacelle Halves

Push terminals through two lengths of conduit to wire end
of socket or pin housing. For best results, push one wire
through conduit at a time.

See

Figure 7-73

and refer to

Table 7-17

. Install terminals

into socket or pin housing.

NOTE

For instructions on properly installing wire terminals, see

A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR

Snap switch bracket into molded retainer in instrument
nacelle.

See

Figure 7-74

. Install right side of instrument nacelle on

motorcycle.

See

Figure 7-71

. Connect speaker switch connector [105],

4-place Multilock.

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

Install two screws (with flat washers) to fasten right side
instrument nacelle to upper and lower fork brackets.
Alternately tighten screws to 15-20 ft-lbs (20-27 Nm).

HOME

2011 Touring Service: Electrical 7-57

Looking into instrument nacelle, connect instruments and
indicator lights to interconnect harness as follows:

Speedometer connector [39], 12-place Packard.

Tachometer connector [108], 12-place Packard.

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

10. Verify that left and right sides of instrument nacelle are

properly mated. Pins on left side of nacelle must fully
engage holes on right.

11. Insert tab at rear of bezel into slot of instrument nacelle

(just in front of ignition switch). Holding left and right sides
of nacelle together, place bezel over instrument nacelle
flange. When properly mated, tabs at front of instrument

nacelle engage lip in slot at front of bezel (behind decor-
ative adhesive strip).

NOTE

If tabs do not properly engage slot at front of bezel, then a
loose fit will result. Remove decorative adhesive strip by gently
prying up outer edges, and using a flat bladed screwdriver,
carefully raise tabs so that they engage lip in slot. If damaged,
install new decorative adhesive strip.

12. Install screw on each side of bezel. Alternately tighten

screws to 25-35

in-lbs

(2.8-4.0 Nm).

13. Assemble ignition switch. See

7.17 IGNITION/LIGHT KEY

SWITCH AND FORK LOCK

HOME

7-58 2011 Touring Service: Electrical

7.20

CRANKSHAFT POSITION SENSOR (CKP)

GENERAL

The crank position sensor is a variable reluctance (VR) sensor
that generates an AC signal by sensing the passing of the 30
teeth machined in the left side flywheel. Two consecutive teeth
are missing in the flywheel to establish a reference point. The
crank position sensor sends a signal to the electronic control
module which is used to reference engine position (TDC) and
engine speed.

NOTE

CKP sensor connector is not serviceable. If connector or sensor
fails, the entire assembly must be replaced.

REMOVAL

Remove main fuse. See

7.7 SYSTEM FUSES AND

RELAYS

Locate CKP sensor connector [79], 2-place Deutsch, fixed
to front caddy at bottom of lower frame crossmember.

Push connector toward right side of motorcycle to disen-
gage small end of slot on attachment clip from T-stud on
front caddy. Lift connector off T-stud.

Press button on socket terminal side and pull apart pin
and socket halves.

See

Figure 7-75

and

Figure 7-76

. Remove screw to free

CKP sensor mount from front left side of crankcase. Pull
sensor from bore.

INSTALLATION

Install

new

O-ring on sensor body if missing, distorted,

pinched or otherwise damaged. Apply a thin film of clean
H-D 20W50 engine oil to O-ring before installation.

See

Figure 7-75

. Push sensor into bore aligning hole in

sensor mount with hole in spot face. Install screw and
tighten to 90-120

in-lbs

(10.2-13.6 Nm).

Route connector and convoluted tubing downward at rear
of front engine stabilizer link to front caddy at bottom of
lower frame crossmember.

Mate pin and socket halves of CKP sensor connector [79].

sm03463

Figure 7-75. Remove CKP Sensor Mount Screw

sm02543

Figure 7-76. CKP Sensor O-Ring

Place large end of slot on attachment clip over T-stud on
front caddy. Push connector toward left side of motorcycle
to engage small end of slot.

Install main fuse. See

7.7 SYSTEM FUSES AND RELAYS

HOME

2011 Touring Service: Electrical 7-59

7.21

AUTOMATIC COMPRESSION RELEASE (ACR)

GENERAL

NOTE

ACR is used only on 103 cu. in. and larger engines.

See

Figure 7-77

. The Automatic Compression Release (ACR)

is opened and closed by the ECM to assist starting.

See

Figure 7-78

. When open, compressed gases are released

through the exhaust port.

REMOVAL

TOOL NAME

PART NUMBER

ACR SOLENOID SOCKET

HD-48498-A

Remove the rocker cover and the rocker box. See

3.12 TOP END SERVICE

Separate the ACR rear [203R] or front [203F] connector
from the main wiring harness and remove connectors from
retainer clip.

See

Figure 7-82

. Use ACR SOLENOID SOCKET (Part

No. HD-48498-A) to remove the ACR from the cylinder
head.

ed01623

Figure 7-77. ACR Valve in Combustion Chamber

ed01624

Figure 7-78. ACR Exhaust Port Release

sm06230

Figure 7-79. ACR in Head

INSTALLATION

TOOL NAME

PART NUMBER

ACR SOLENOID SOCKET

HD-48498-A

Verify that the copper seal washer is in place on the ACR.

See

Figure 7-80

. Identify a location around the threads of

the ACR approximately 1/3 of the way up from the end.

See

Figure 7-81

. Apply three equally spaced dots of

LOCTITE

246

THREADLOCKER

MEDIUM

STRENGTH/HIGH TEMPERATURE (blue) on threads.

To prevent cross threading, install and finger tighten.

See

Figure 7-82

. Using ACR SOLENOID SOCKET (Part

No. HD-48498-A), tighten to 11-15 ft-lbs (14.9-20.3 Nm).

Route the wire harness between the cylinder V.

Install rocker box and rocker cover. See

3.12 TOP END

SERVICE

HOME

7-60 2011 Touring Service: Electrical

Mate the ACR connectors [203R] and [203F] to the main
wiring harness. Secure connectors to retaining clip.

ed01626

Figure 7-80. Bottom Third

ed01627

Figure 7-81. Three Dots of Loctite 246 Medium

Strength/High Temperature

sm06232

Figure 7-82. ACR Solenoid Socket and ACR

HOME

2011 Touring Service: Electrical 7-61

7.22

ALTERNATOR

REMOVAL

Remove seat. See

2.25 SEAT

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Remove battery negative (-) cable (black) from battery.

Remove the primary chaincase. See

5.5 PRIMARY

CHAINCASE HOUSING

The high-output rotor contains powerful magnets. Exercise
caution to prevent possible hand injury during removal
and installation. (00558b)

Using allen wrenches or similar tools through holes in
rotor, pull rotor from the engine compensating sprocket
shaft.

See

Figure 7-83

. Release locking latch and remove con-

nector (1) from regulator.

Cut anchored cable strap securing stator wiring to frame.

Remove four screws to free stator from crankcase. Discard
screws.

NOTES

•

Note positions of grommet O-rings before removal.

•

Do not damage O-ring grooves when removing O-rings.

See

Figure 7-84

. Remove and discard retention O-ring (3)

from stator grommet. Squirt isopropyl alcohol or glass
cleaner into opening.

While pushing on the grommet from outside of crankcase,
draw grommet through the bore by pulling on inside of
grommet with needle nose pliers. Do not pull on the wires
unless the stator is to be replaced. Exercise caution to
avoid damaging grommet if stator is to be reused.

10. Draw conduit and connector through crankcase bore as

stator is removed.

11. Remove and discard sealing O-rings (2).

sm03470a

1. Stator connector [46]
2. Voltage regulator output connector [77]

Figure 7-83. Voltage Regulator (Left Side View)

sm06986

1. To voltage regulator
2. Sealing O-rings
3. Retention O-ring

Figure 7-84. Stator Grommet

CLEANING AND INSPECTION

Remove all foreign particles from rotor magnets. Clean
rotor by wiping thoroughly with a clean cloth.

Replace rotor if magnets are cracked or loose, stator bolts
have loosened and contacted rotor, or there is evidence
of spline damage on the rotor center mounting bolt hole.

HOME

7-62 2011 Touring Service: Electrical

Clean stator, stator leads and grommet thoroughly with a
clean cloth. Examine stator leads for cracked or damaged
insulation.

Replace stator if there are any signs of contact with rotor,
insulation is damaged or cracked, or stator fails any stator
electrical tests. See the electrical diagnostic manual.

NOTE

The rotor and stator can be replaced individually if either is
damaged.

INSTALLATION

See

Figure 7-84

. Install

new

sealing O-rings (2) on

grommet.

Feed connector and conduit through hole in crankcase
from inside crankcase.

Thoroughly lubricate O-rings with isopropyl alcohol or glass
cleaner. O-rings must be clean and free of dirt and oily
residue.

Carefully grasp cable stop behind grommet with a needle
nose pliers. Push grommet into crankcase bore while
carefully pulling on outside cable. Push grommet until it
is seated in crankcase.

Install retaining O-ring (3) on grommet.

Push grommet into crankcase bore. Installation is complete
when retaining O-ring bottoms on casting.

NOTE

Do not reuse stator mounting screws. The threads of the screws
contain a locking compound in pellet form. When the screw is
started, the pellet breaks, releasing the compound.

Secure stator to crankcase using four

new

screws. Tighten

screws to 55-75

in-lbs

(6.2-8.5 Nm).

See

Figure 7-85

. Install

new

anchored cable strap (1) on

stator wiring (2) and push anchor into hole in frame.

Install connector to voltage regulator and engage locking
latch.

The high-output rotor contains powerful magnets. Exercise
caution to prevent possible hand injury during removal
and installation. (00558b)

10. Using allen wrenches or similar tools through holes in

rotor, ease rotor onto the engine compensating sprocket
shaft.

11. Install the primary chaincase. See

5.5 PRIMARY CHAIN-

CASE HOUSING

12. Connect battery negative cable (black) to battery negative

(-) terminal. Tighten bolt to 60-70

in-lbs

(6.8-7.9 Nm).

13. Install seat. See

2.25 SEAT

sm06181

1. Anchored cable strap
2. Stator wiring

Figure 7-85. Stator Wiring

HOME

2011 Touring Service: Electrical 7-63

7.23

VEHICLE SPEED SENSOR (VSS)

VSS

Removal

Remove starter. See

7.10 STARTER

See

Figure 7-86

. Disconnect VSS connector [65], 3-place

Delphi.

Remove screw and pull sensor from transmission case.

Installation

Inspect VSS O-ring for cuts, tears or general deterioration.
Replace as necessary.

Insert sensor into transmission case. Install screw and
tighten to 84-132

in-lbs

(9.5-14.9 Nm).

Connect VSS connector [65], 3-place Delphi.

Install starter. See

7.10 STARTER

sm03705

Figure 7-86. VSS Location

HOME

7-64 2011 Touring Service: Electrical

7.24

NEUTRAL SWITCH

REMOVAL

Verify that transmission is in NEUTRAL.

See

Figure 7-87

. Remove two elbow connectors from

neutral switch posts.

Remove neutral switch from transmission case.

INSTALLATION

See

Figure 7-88

. Inspect O-ring for cuts, tears or general

deterioration. Replace as necessary. Lightly lubricate

new

O-ring with clean transmission oil before installation.

Verify that transmission is in NEUTRAL.

Install neutral switch in transmission case and tighten to
120-180

in-lbs

(13.6-20.3 Nm).

NOTE

The neutral switch is not polarity sensitive. Install the elbow
connectors on either post.

Install two elbow connectors onto neutral switch posts.

Test neutral switch for proper operation as follows:

Verify that transmission is in NEUTRAL.

Turn Ignition/Light Key Switch to IGNITION.

Verify that neutral indicator light illuminates.

sm05247

Figure 7-87. Neutral Switch

sm05246

Figure 7-88. Neutral Switch O-Ring

HOME

2011 Touring Service: Electrical 7-65

7.25

OIL PRESSURE SWITCH AND SENDER

REMOVAL

FLHR/C:

See

Figure 7-89

. Remove elbow connector (1)

from post terminal of oil pressure switch (2).

FLHX, FLHTC/U, FLHTK, FLTRX, FLTRU:

Remove 4-

place Delphi connector (3) from oil pressure sender (4).

Remove switch or sender from crankcase.

INSTALLATION

NOTE

If reusing oil pressure switch/sender, apply Loctite Pipe Sealant
with Teflon 565 to threads.

See

Figure 7-89

. Start oil pressure switch or sender into

crankcase bore.

FLHR/C:

Tighten oil pressure switch to 96-144

in-lbs

(10.8-

16.3 Nm).

Install elbow connector (1) onto post terminal.

FLHX, FLHTC/U, FLHTK, FLTRU, FLTRX:

Tighten oil pressure sender to 96-144

in-lbs

(10.8-

16.3 Nm).

Install 4-place Delphi connector (3).

NOTE

Be sure harness is routed outside frame rail as shown.

Test oil pressure switch/sender for proper operation and
check for leaks.

sm06058

1. Elbow connector
2. Oil pressure switch
3. Delphi connector
4. Oil pressure sender

Figure 7-89. Oil Pressure Switch/Sender

HOME

7-66 2011 Touring Service: Electrical

7.26

STOPLIGHT SWITCHES

FRONT STOPLIGHT SWITCH

Removal/Installation

See

7.40 HANDLEBAR SWITCH ASSEMBLIES

REAR STOPLIGHT SWITCH

Removal

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTE

Immediately wipe up any brake fluid spillage with a clean, dry,
soft cloth. Follow up by thoroughly wiping affected area with a
clean, damp, soft cloth (small spills) or washing with a large
quantity of soapy water (large spills).

See

Figure 7-90

. Remove wire connectors (1).

NOTE

Wrap rear brake line with piece of shop towel to absorb any
loss of brake fluid.

Hold brake line fitting (3) and remove rear stoplight switch
(2).

Installation

Apply Loctite Pipe Sealant with Teflon 565 to threads of
rear stoplight switch.

See

Figure 7-90

. Install rear stoplight switch (2) into rear

brake line fitting (3).

Hold brake line fitting and tighten rear stoplight switch to
12-15 ft-lbs (16.3-20.3 Nm).

Fill and bleed rear brake system. See

2.16 BLEEDING

BRAKES

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

Verify proper operation of tail lamp/rear brake light.

sm03703a

1. Wire connectors
2. Stoplight switch
3. Brake line fitting

Figure 7-90. Rear Stoplight Switch

HOME

2011 Touring Service: Electrical 7-67

7.27

HORN

INSPECTION

If the horn fails to sound or does not sound satisfactorily, check
for loose, frayed or damaged wires leading to horn terminal,
discharged battery or corroded ground.

The horn is permanently sealed and non-repairable. Only the
mounting hardware is replaceable.

NOTE

No tonal adjustments may be made to this horn.

REMOVAL

Remove acorn nut and flat washer to free horn assembly
from rubber mount stud.

Remove elbow terminals from spade contacts and release
main harness conduit from J-clamp.

Remove flange nut (10mm) from circular recess at back
of horn bracket. Remove horn from chrome horn cover.

INSTALLATION

Fit horn into chrome cover so that stud at back slides
through hole in horn bracket. Apply two drops of Loctite
Low Strength Threadlocker 222 (purple) to threads of horn
stud.

NOTE

Overtightening the flange nut can cause permanent horn
damage resulting in reduced volume and tone quality.

Install flange nut (10mm) on horn stud and tighten to 80-
100

in-lbs

(9.0-11.3 Nm).

Install elbow terminals onto spade contacts.

NOTE

The horn is not polarity sensitive. Elbow terminals may be
attached to either spade contact.

Capture main harness conduit in J-clamp and install horn
bracket onto rubber mount stud. Install flat washer and
acorn nut. Tighten acorn nut to 80-120

in-lbs

(9.0-13.6

Nm).

HOME

7-68 2011 Touring Service: Electrical

Table B-1. Connector Locations

LOCATION

TERMINAL

PROBE
COLOR

TYPE

DESCRIPTION

NO.

Inside Tour-Pak (FLHTK)

Gray

2-place Tyco 070 Multilock
Unsealed (BK)

Power outlet

[258]

Rear fender tip fascia module (FLHX,
FLTRX)

Breakout Box

12-place Delphi Micro 64
Sealed (GY)

Rear lighting jumper harness

[262]

Under seat

Ring terminals

Harness grounds

[GND1]

[GND1A]

[GND2]

HOME

B-6 2011 Touring Service: Appendix B Wiring

B.2

WIRING DIAGRAMS

WIRING DIAGRAM INFORMATION

Wire Color Codes

Wire traces on wiring diagrams are labeled with alpha codes.
Refer to

Table B-2

For Solid Color Wires:

See

Figure B-1

. The alpha code

identifies wire color.

For Striped Wires:

The code is written with a slash (/) between

the solid color code and the stripe code. For example, a trace
labeled GN/Y is a green wire with a yellow stripe.

Wiring Diagram Symbols

See

Figure B-1

. On wiring diagrams and in service/repair

instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing
is a socket or pin housing.

A=Pin:

The letter A and the pin symbol after a connector

number identifies the pin side of the terminal connectors.

B=Socket:

The letter B and the socket symbol after a connector

number identifies the socket side of the terminal connectors.
Other symbols found on the wiring diagrams include the fol-
lowing:

Diode:

The diode allows current flow in one direction only in

a circuit.

Wire break:

The wire breaks are used to show option variances

or page breaks.

No Connection:

Two wires crossing over each other in a wiring

diagram that are shown with no splice indicating they are not
connected together.

Circuit to/from:

This symbol is used to identify there is a more

complete circuit diagram on another page. The symbol is also
identifying the direction of current flow.

Splice:

Splices are where two or more wires are connected

together along a wiring diagram. The location of the splice
indicated in the wiring diagram is not the true location of the
splice in the actual harness but to identify that the wires are
spliced to that circuit.

Ground:

Grounds can be classified as either clean or dirty

grounds. Clean grounds are identified by a (BK/GN) wire and
are normally used for sensors or modules. These grounds
usually do not have electric motors, coils or anything that may
cause electrical interference on the ground circuit. The dirty
grounds are identified by a (BK) wire and are used for compon-
ents that are not as sensitive to electrical interference.

Twisted pair:

This symbol indicates the two wires are twisted

together in the harness. This minimizes the circuit's electromag-
netic interference from external sources. If repairs are neces-
sary to these wires they should remain as twisted wires.

GN/Y

[21A]

[21B]

ed03175

1. Connector number
2. Terminal code (A=pin, B=socket)
3. Solid wire color
4. Striped wire color
5. Socket symbol
6. Pin symbol
7. Diode
8. Wire break
9. No connection
10. Circuit to/from
11. Splice
12. Ground
13. Twisted pair

Figure B-1. Connector/Wiring Diagram Symbols

HOME

2011 Touring Service: Appendix B Wiring B-7

64-1

64-2

ed03115

1. Fuse block [64-1]
2. Brake
3. Accessory
4. P&A
5. Radio power/siren
6. Radio memory
7. Battery
8. ECM power
9. Pwr outlet
10. Exhaust CNTRL
11. System relay
12. Start relay
13. Fuel pump
14. Fuse block [64-2]
15. Instruments
16. Ignition
17. Lighting relay
18. Brake relay
19. Headlamp
20. Lights
21. Spare
22. ABS
23. Spare

Figure B-2. Fuse Block and Socket Terminals

Table B-2. Wire Color Codes

WIRE COLOR

ALPHA CODE

Blue

Black

Brown

Green

Grey

Light Green

LGN

Orange

Pink

Red

Tan

Violet

White

Yellow

HOME

B-8 2011 Touring Service: Appendix B Wiring

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