Harley Davidson 2011 Touring Models. Service Manual - page 42

10. Install left side cover.

11. Install left side saddlebag. See

12. Install outer fairing. See

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS

sm06047

1. Fender support (tree mount)
2. Air valve bracket
3. Saddlebag support

Figure 7-123. Radio Antenna Cable Routing

7-100 2011 Touring Service: Electrical

7.38

REAR AUDIO HARNESS: ULTRA MODELS

REMOVAL

Remove fuel tank. See

Remove saddlebags. See

Remove both side cover.

Remove outer fairing. See

See

Figure 7-124

. Disconnect the following connectors:

CB antenna cable (3).

Audio to interconnect harness (1).

Radio (2).

CB module (4).

Remove rivet and P-clamp securing audio and main har-
ness to left side of steering head.

Pull audio harness rearward and out of fairing cap.

Remove map pocket and molded liner from Tour-Pak.

See

Figure 7-125

. Disconnect CB antenna cable connector

(1). Release cable from adhesive clip (2).

10. Pull grommet (3) into Tour-Pak and remove from CB

antenna cable. Pull CB antenna cable out through hole.

11. Draw rear speaker/passenger controls connector out of

right side speaker box and disconnect. Repeat with left
speaker harness.

12. Cut cable straps securing audio harnesses and CB

antenna cable to luggage rack rails.

13. Release rear headset receptacle from bracket at bottom

of left side speaker box and disengage spring.

14. Release console connector [53], 12-place Deutsch, from

attachment clip anchored in hole of frame weldment at
rear of battery tray. Disconnect connector.

15. Cut four cable straps securing audio harness to left and

right upper frame tubes.

16. Remove cover from wire trough.

17. Using a paint pen, draw a line on the audio harness con-

duit where it enters and exits the wire trough.

18. Draw a line on both sides of each cable strap that captures

the audio harness. Carry the line over onto the main har-
ness where possible.

19. Cut and remove cables straps to free audio harness.

20. Remove audio harness from motorcycle.

sm05185

1. Audio to interconnect harness [6]
2. Radio [28]
3. CB antenna cable [50]
4. CB module [184]

Figure 7-124. Audio Harness Connectors

sm03547a

1. CB antenna cable connector [104]
2. Adhesive clip
3. Grommet

Figure 7-125. CB Antenna Cable Connector [104]

INSTALLATION

Lay

new

and used audio harnesses side by side. Transfer

painted lines onto

new

harness.

Install

new

cable straps through slots of wire trough where

removed.

2011 Touring Service: Electrical 7-101

NOTE

If additional clearance is needed for installation of the cable
straps, pry up rear of wire trough to release anchor pins from
holes in frame backbone. Install wire trough after placement
of cable straps.

Adjust main harness as necessary, so that the painted
lines are aligned with the cable straps installed in the wire
trough.

Place audio harness on top of main harness aligning the
entrance and exit lines with the wire trough. Verify that
branch containing rear headset receptacle exits left side
of wire trough and branch containing CB antenna cable
connector exits right side.

Engage end of each cable strap into eyelet, but do not
tighten.

Route front section of audio harness along left side of
steering head and up toward radio.

Install connectors in radio and CB module.

Secure audio and main harness to left side of steering
head using P-clamp and

new

rivet.

Route right harness branch along inboard side of right
upper frame tube and up the luggage rack rail to speaker.
Route CB antenna cable through hole in Tour-Pak.

10. Loosely install

new

cable straps to secure audio harness

to right upper frame tube and luggage rack rail.

11. Install grommet in Tour-Pak with the larger OD facing

inside.

12. Connect CB antenna cable connector and capture cable

in adhesive clip at bottom of Tour-Pak.

13. Connect right speaker/passenger controls connector. Feed

connector into speaker box pressing trim ring into hole.

14. Tighten cable straps securing right-side harness to frame

and luggage rack. Remove excess strap material.

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

connector onto attachment clip anchored in hole of frame
weldment at rear of battery tray.

16. Route left harness branch along inboard side of left upper

frame tube, up luggage rack rail to speaker.

17. Connect left speaker/passenger controls connector. Feed

connector into speaker box pressing trim ring into hole.

18. Connect spring loop of rear headset receptacle onto tab

on right side of license plate bracket. Capture headset
receptacle in bracket.

19. Loosely install

new

cable straps to secure audio harness

to left upper frame tube and luggage rack rail.

20. Install molded liner and map pocket in Tour-Pak.

21. Make final adjustments to harness, so that painted lines

are aligned with cable straps. Tighten all cable straps and
cut excess strap material.

22. Install cover on wire trough. Verify that all latches are fully

engaged.

23. Install fuel tank. See

24. Install side covers and saddlebags, right side first. See

25. Install outer fairing. See

7-102 2011 Touring Service: Electrical

7.39

CB ANTENNA CABLE: ULTRA MODELS

REMOVAL

Remove fuel tank. See

Remove right side saddlebag. See

Remove right side cover.

Remove outer fairing. See

See

Figure 7-126

. Disconnect CB antenna cable connector

from CB module. Carefully cut cable where it exits audio
harness conduit.

Remove cover from wire trough.

Carefully cut two cable straps securing audio harness to
right upper frame tube and one securing audio harness
to luggage rack rail.

Remove map pocket and molded liner from Tour-Pak.

See

Figure 7-127

. Disconnect CB antenna cable connector

(1). Release cable from front adhesive clip (2).

10. Pull grommet (3) into Tour-Pak and remove from CB

antenna cable. Pull CB antenna cable out through hole at
front of Tour-Pak.

11. Cut CB antenna cable where it exits audio harness conduit.

sm02962

Figure 7-126. CB Antenna Cable Connector [50]

sm03547a

1. CB antenna cable connector [104]
2. Adhesive clip
3. Grommet

Figure 7-127. CB Antenna Cable Connector [104]

INSTALLATION

Connect CB antenna cable connector to CB module.

Route free end of CB antenna cable rearward along left
side of steering head and through wire trough. Exit wire
trough at rear right side and route cable along inboard
side of right upper frame tube, following luggage rack rail
and into front of Tour-Pak.

Remove rivet and P-clamp to release audio and main
harness conduit from left side of steering head. Capture
CB antenna cable in P-clamp and install.

Loosely install two

new

cable straps to secure CB antenna

cable and audio harness to right upper frame tube.

See

Figure 7-128

. Loosely install

new

cable strap to

secure CB antenna cable and audio harness conduit to
luggage rack rail. Loosely install

new

cable strap to secure

CB antenna cable to speaker/passenger controls conduit.

Install grommet in Tour-Pak with the larger OD facing
inside.

Connect CB antenna cable connector. Capture cable in
front adhesive clip at bottom of Tour-Pak.

Tighten all cable straps securing CB antenna cable.
Remove excess cable strap material.

Install molded liner and map pocket in Tour-Pak.

10. Install cover on wire trough. Verify that all latches are fully

engaged.

11. Install fuel tank. See

12. Install right side cover.

13. Install right side saddlebag. See

14. Install outer fairing. See

2.23 HANDLEBARS, Left Handgrip

2011 Touring Service: Electrical 7-103

7.40

HANDLEBAR SWITCH ASSEMBLIES

REMOVAL

NOTES

•

While there are four different switch configurations for
Touring models (Road King, Road King Classic, Classic
and Ultra), the removal procedures are the same. To
simplify these instructions, only the Road King switch
configuration is represented in the photographs and illus-
trations which follow.

•

Replacement switches come with adequate wire to replace
the switch and run the new wire to the appropriate con-
nector. You may choose to replace the complete switch
and wire and terminate it at the appropriate connector or
use the splicing procedure explained in this section

Right Handlebar Controls

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

NOTE

Use the eyelet of a cable strap if the cardboard insert is not
available.

See

Figure 7-129

. Place cardboard insert between brake

lever and lever bracket.

Remove two screws (with flat washers) securing handlebar
clamp to master cylinder housing. Remove brake
lever/master cylinder assembly and clamp from handlebar.

Remove upper and lower switch housing screws.

Remove friction shoe from end of tension adjuster screw
(non cruise equipped models only).

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if lower switch housing is turned upside down or shaken.

Cut two cable straps to release wire harness conduit from
handlebar, if present.

sm05016

1. Tab
2. Groove
3. Switch housing assembly
4. Brake lever bracket
5. Cardboard insert

Figure 7-129. Remove Master Cylinder/Brake Lever

Assembly

Left Handlebar Controls

Remove two screws (with flat washers) securing handlebar
clamp to clutch lever bracket. Remove clutch hand lever
assembly and clamp from handlebar.

Remove upper and lower switch housing screws.

Cut two cable straps to release wire harness conduit from
handlebar, if present.

Remove hand grip from handlebar, if damaged. See

DISASSEMBLY

Right Side Handlebar Switches

NOTE

Use the eyelet of a cable strap if the cardboard insert is not
available.

Place cardboard insert between brake lever and lever
bracket.

Remove upper and lower switch housing screws.

7.40 HANDLEBAR SWITCH ASSEMBLIES, Specific
Repair Procedures: Upper Switch Housings

2011 Touring Service: Electrical 7-105

If replacing lower housing switches, proceed to next step.
If

replacing

upper

housing

switches,

proceed

Loosen upper screw securing handlebar clamp to master
cylinder housing. Remove lower clamp screw (with flat
washer).

Remove friction shoe from end of tension adjuster screw
(non cruise equipped models only).

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if lower switch housing is turned upside down or shaken.

Left Side Handlebar Switches

Remove upper and lower switch housing screws.

If replacing lower housing switches, proceed to next step.
If

replacing

upper

housing

switches,

proceed

7.40 HANDLEBAR SWITCH ASSEMBLIES, Specific
Repair Procedures: Upper Switch Housings

Loosen upper screw securing handlebar clamp to clutch
lever bracket. Remove lower clamp screw (with flat
washer).

SPECIFIC REPAIR PROCEDURES: UPPER
SWITCH HOUSINGS

NOTES

•

Regardless of model or option, all motorcycles use the
same upper switch housings.

•

Replace Engine Stop and Engine Start Switches as a
single assembly even if only one switch is determined to
be faulty.

Right Side Handlebar (All Models)

See

Figure 7-130

. From inside switch housing, remove

screw to release bracket. Remove bracket and switch
assembly from housing.

Move cable conduit from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches. Discard old
switch and bracket assembly.

Slide conduit forward over severed ends of switch wires
and cut off 0.5 in. (12.7 mm) of conduit material. Push
conduit back to access switch wires.

Separate

new

Engine Stop Switch and Start Switch wires

into two bundles.

NOTE

Replacement Stop Switch and Start Switch wires are cut to
length, 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm), respectively,
and partially stripped.

Splice wires together. See

Loop switch wires so that spliced lengths are positioned
as shown in

Figure 7-131

. Route wires downstream of

splices beneath wing on Engine Stop Switch side of
bracket as shown in

Figure 7-130

Install

new

7.0 in. (178 mm) cable strap beneath wing on

Engine Start Switch side of bracket and capture wire
splices.

Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that bracket
is fully seated. The step at edge of boss captures bottom
edge of bracket, while tabs on each side of bracket fit in
slots cast into housing.

See

Figure 7-130

. Install screw to secure bracket inside

housing. Verify that wing on Engine Stop Switch side of
bracket captures edge of conduit.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

11. Complete assembly. See

ASSEMBLIES, Assembly: Right Side Handlebar Switches

NOTE

Replace Horn and High/Low Beam Switches as a single
assembly even if only one switch is determined to be faulty.

sm01368

1. Start switch
2. Stop switch
3. Conduit
4. Screw with lock washer
5. Bracket

Figure 7-130. Upper Right Handlebar Switch Housing

(Without Splices)

7-106 2011 Touring Service: Electrical

sm01369

1. Start switch
2. Stop switch
3. Conduit
4. Splices
5. Cable strap

Figure 7-131. Upper Right Handlebar Switch Housing (With

Splices)

Left Side Handlebar (All Models)

See

Figure 7-132

. From inside switch housing, remove

screw to release bracket. Remove bracket and switch
assembly from housing.

Move cable conduit from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches. Discard old
switch and bracket assembly.

Slide conduit forward over severed ends of switch wires
and cut off 0.5 in. (12.7 mm) of conduit material. Push
conduit back to access switch wires.

Separate

new

Horn and High/Low Beam Switch wires into

two bundles.

NOTE

Replacement High/Low Beam Switch and Horn Switch wires
are cut to length, 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm),
respectively, and partially stripped.

Splice wires together. See

Loop switch wires so that spliced lengths are positioned
as shown in

Figure 7-133

. Route wires downstream of

splices beneath wing on High/Low Beam Switch side of
bracket as shown in

Figure 7-132

Install

new

7.0 in. (178 mm) cable strap beneath wing on

Horn Switch side of bracket and capture wire splices.

See

Figure 7-132

. Install screw to secure bracket inside

housing. Verify that wing on High/Low Beam Switch side
of bracket captures edge of conduit.

10. See

Figure 7-133

. Securely tighten cable strap to draw

splices to bracket. Remove any excess cable strap
material.

11. Complete assembly. See

ASSEMBLIES, Assembly: Right Side Handlebar Switches

sm01371

1. Horn switch
2. High/low beam switch
3. Conduit
4. Screw with lock washer
5. Bracket

Figure 7-132. Upper Left Handlebar Switch Housing

(Without Splices)

2011 Touring Service: Electrical 7-107

sm00086

1. Horn switch
2. High/low beam switch
3. Conduit
4. Splices
5. Cable strap

Figure 7-133. Upper Left Handlebar Switch Housing (With

Splices)

SPECIFIC REPAIR PROCEDURES: RIGHT
SIDE LOWER SWITCH HOUSINGS

Preliminary Instructions

From inside switch housing, carefully cut cable strap to
free conduit from turn signal switch bracket, if present.

Remove screw to release turn signal switch bracket.
Remove bracket and switch assembly from housing.

NOTE

On Classic and Ultra models, pull conduit back to introduce
some slack in wires or the tight fit of the bundle will prevent
removal of turn signal switch bracket.

Turn-Right Signal Switch (All Models)

Cut wires 1.5 in. (38.1 mm) from old switch. Discard old
switch assembly.

NOTE

Replacement Turn-Right Signal Switch wires are cut to length,
1.5 in. (38.1 mm), and partially stripped.

Complete assembly. See

Front Stoplight Switch (All Models)

Carefully remove wedge between switch and switch
housing, if present. To remove switch from housing, press
plunger and slowly rotate switch upward while rocking
slightly.

Cut wires 1.0 in. (25.4 mm) from old switch. Discard old
switch.

NOTE

Replacement stoplight switch wires are cut to length, 2.5 in.
(63.5 mm), and partially stripped.

Complete assembly. See

Carefully press plunger against inside wall of switch
housing. With thumb over plunger bore, move switch into
installed position in switch housing cavity. When plunger
is positioned against thumb, slowly rotate switch downward
while rocking slightly. Release plunger only after switch
is properly positioned in cavity.

Verify that plunger is square in bore and that boot is not
compressed, collapsed or torn. If necessary, gently work
plunger in and out until boot is fully extended.

See

Figure 7-134

. Push down on switch, so that it bottoms

against housing and wires run in groove at base of cavity.
With concave side facing outward, insert wedge between
switch and outboard side of switch housing.

Push wedge down until it also bottoms against housing.
Verify that plunger is still square in bore and then place a
drop of RTV Silicone Sealant on upper corner of wedge.

Mode Select Switch (Classic and Ultra
Models)

Pull keycap from switch shaft.

See

Figure 7-135

. Remove two lower bracket screws. Pull

bracket and switch from switch housing.

Cut wires 1.25 in. (31.8 mm) from old switch. Discard
switch assembly.

NOTE

Replacement Mode Select Switch wires are cut to length, 2.25
in. (57.2 mm), and partially stripped.

Complete assembly. See

Fit

new

switch into cavity, so that it sits on edge in a ver-

tical position (gray/white wire topside). Properly installed,
switch is captured by blocks cast into lower housing. Verify
that switch shaft is aligned for proper keycap operation.

Place lower bracket into housing (with weld nut side down),
but keep splices above bracket. Verify that slots in upper
step of bracket engage two tabs on switch body.

Install shorter screw to secure front side of lower bracket
to threaded boss. Install longer rear screw. To engage
threaded hole in casting, use thru hole in lower step of
bracket on Classic models, thru hole in upper step on
Ultra.

Install keycap on switch shaft.

7-108 2011 Touring Service: Electrical

sm00080

1. Stoplight switch
2. Wedge
3. Switch wires
4. Lower switch housing

Figure 7-134. Install Stoplight Switch

sm03693

1. Turn signal switch bracket screw
2. Lower bracket screw
3. Cable strap

Figure 7-135. Lower Right Handlebar Switch Housing

(Without Splices) - Classic/Ultra Models

sm00081

1. Cable strap
2. Bracket
3. Right turn signal switch

Figure 7-136. Insert Cable Strap in Switch Bracket

Cruise Set/Resume Switch (Road King
Classic and Ultra Models)

Pull keycap from switch shaft.

Remove two lower bracket screws. Pull bracket and switch
from switch housing.

Cut wires 1.5 in. (38.1 mm) from old switch. Discard switch
assembly.

NOTE

Replacement Cruise Set/Resume Switch wires are cut to
length, 2.0 in. (50.8 mm), and partially stripped.

Complete assembly. See

Fit

new

switch into cavity, so that it sits in a horizontal

position (blue/black wire towards master cylinder). Properly
installed, switch is captured by blocks cast into lower
housing.

Keeping splices above bracket, install lower bracket (weld
nut side down), so that lower step is positioned over
switch. Slots in upper step engage two tabs on plastic
insert (Road King Classic) or on body of Mode Select
Switch (Ultra models).

NOTE

The Mode Select Switch is vertically oriented with the
gray/white wire topside.

Install shorter screw to secure front side of lower bracket
to threaded boss. Install longer rear screw. Use thru hole

2011 Touring Service: Electrical 7-109

in upper step of bracket to engage threaded hole in
casting.

Note lettering for proper orientation and gently push
keycap onto switch shaft.

Final Instructions

See

Figure 7-136

. Insert tapered end of

new

7.0 in. (178

mm) cable strap into round hole in turn signal switch
bracket and then feed back through using adjacent hole.
Reserve oblong hole for bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal
switch bracket.

Place turn signal switch assembly into housing aligning
oblong hole in bracket with lower bracket weld nut
(threaded boss on Road King Standard models). Be sure
that bracket is fully seated. Tabs on each side of bracket
are captured in slots cast into switch housing.

Start screw to secure bracket inside housing.

If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)

Loop switch wires, so that spliced lengths are positioned
as shown in

Figure 7-137

Figure 7-138

Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.

Install second 7.0 in. (178 mm) cable strap capturing
conduit and wire splices. Securely tighten cable strap to
draw splices to conduit. Remove any excess cable strap
material.

Tighten screw to secure bracket inside housing.

Route wire bundle to upper switch housing by gently
pressing conduit into channel next to angular arm of
bracket. Secure bundle to arm using third cable strap.

Cut any excess cable strap material. If necessary, bend
angular arm of bracket downward to firmly secure Front
Stoplight Switch in installed position.

Complete assembly. See

sm03694

1. Angular arm
2. Cable strap (wire bundle to arm)
3. Cable strap (conduit to bracket)
4. Cable strap (splices to conduit)
5. Splices

Figure 7-137. Mode Select Handlebar Switch Housing

(Lower Right) - Classic/Ultra Models

7-110 2011 Touring Service: Electrical

sm03695

1. Angular arm
2. Cable strap (wire bundle to arm)
3. Cable strap (conduit to bracket)
4. Cable strap (splices to conduit)
5. Splices

Figure 7-138. Cruise Control Handlebar Switch Housing

(Lower Right) - Classic/Ultra Models

SPECIFIC REPAIR PROCEDURES: LEFT
SIDE LOWER SWITCH HOUSINGS

Preliminary Instructions

From inside switch housing, carefully cut cable strap to
free conduit from turn signal switch bracket, if present.

Remove screw to release turn signal switch bracket.
Remove bracket and switch assembly from housing.

NOTE

On Classic and Ultra models, pull conduit back to introduce
some slack in wires or the tight fit of the bundle will prevent
removal of the switch bracket.

Turn-Left Signal Switch (All Models)

Cut wires 1.5 in. (38.1 mm) from old switch. Discard old
switch assembly.

NOTE

Replacement Turn-Left Signal Switch wires are cut to length,
1.5 in. (38.1 mm), and partially stripped.

Complete assembly. See

Clutch Interlock Switch

Cut wires 0.25 in. (6.4 mm) from old switch. Discard switch
assembly.

NOTE

Replacement Clutch Interlock Switch wires are cut to length
and partially stripped. Looking at backside, left side switch wire
is 2.25 in. (57.2 mm) long, right side is 2.75 in. (70 mm) long.

Complete assembly. See

Seat switch in cavity. Verify that plunger is square in bore
and that boot is not compressed, collapsed or torn. Push
down on switch, so that it bottoms against housing and
wires run in groove at base of cavity.

sm03696

1. Clutch interlock switch
2. Left turn signal switch and bracket
3. Lower bracket
4. Audio control switch
5. Audio switch keycap

Figure 7-139. Lower Left Handlebar Switch Assembly

(Classic)

2011 Touring Service: Electrical 7-111

sm03697

1. Lower bracket
2. Right turn signal switch and bracket
3. Stoplight switch
4. Mode select switch
5. Mode select keycap

Figure 7-140. Lower Right Handlebar Switch Assembly

(Classic)

sm03698

1. Clutch interlock switch
2. Left turn signal switch and bracket
3. Lower bracket
4. Audio control switch
5. Audio switch keycap
6. PTT switch
7. PTT switch keycap

Figure 7-141. Lower Left Handlebar Switch Assembly

(Ultra)

sm03699

1. Lower bracket
2. Stoplight switch
3. Right turn signal switch and bracket
4. Cruise control switch
5. Mode select switch
6. Mode select keycap
7. Cruise switch keycap

Figure 7-142. Lower Right Handlebar Switch Assembly

(Ultra)

sm03700

1. Lower bracket screw
2. Turn signal switch bracket screw
3. Cable strap
4. Lower bracket screw

Figure 7-143. Lower Left Handlebar Switch Housing

(Without Splices) - Classic/Ultra Models

7-112 2011 Touring Service: Electrical

Audio Control Switch (Classic and Ultra
Models)

Pull keycap from switch shaft.

See

Figure 7-143

. Remove two lower bracket screws. Pull

bracket and switch from switch housing.

Cut wires 1.25 in. (31.8 mm) from old switch. Discard
switch assembly.

NOTE

Replacement Audio Control Switch wires are cut to length,
2.25 in. (57.2 mm), and partially stripped.

Complete assembly. See

Fit

new

switch into cavity, so that it sits on edge in a ver-

tical position (gray/green wire topside). Properly installed,
switch is captured by blocks cast into lower housing. Verify
that switch shaft is aligned for proper keycap operation.

Place lower bracket into housing (with weld nut side down),
but keep splices above bracket. Verify that slots in upper
step of bracket engage two tabs on switch body.

Note lettering for proper orientation and gently push
keycap onto switch shaft.

CB Push-To-Transmit Switch (Ultra Models)

Pull keycap from switch shaft.

See

Figure 7-143

. Remove two lower bracket screws. Pull

bracket and switch from switch housing.

Cut wires 1.5 in. (38.1 mm) from old switch. Discard switch
assembly.

NOTE

Replacement Push-to-Transmit Switch wires are cut to length,
2.0 in. (50.8 mm), and partially stripped.

Complete assembly. See

Fit

new

switch into cavity, so that it sits in a horizontal

position (brown/black wire towards clutch lever bracket).
Properly installed, switch is captured by blocks cast into
lower housing.

Keeping splices above bracket, install lower bracket (weld
nut side down), so that lower step is positioned over Push-
to-Transmit Switch (horizontally oriented). Slots in upper
step engage two tabs on body of Audio Control Switch
(vertically oriented with gray wire topside).

Install shorter screw to secure front side of lower bracket
to threaded boss. Install longer rear screw. To engage
threaded hole in casting, use thru hole in upper step of
bracket.

Note lettering for proper orientation and gently push
keycap onto switch shaft.

Cruise On/Off Switch (Road King Classic
Models)

Pull keycap from switch shaft.

Remove two lower bracket screws. Pull bracket and switch
from switch housing.

Cut wires 1.5 in. (38.1 mm) from old switch. Discard switch
assembly.

NOTE

Cut replacement Cruise On/Off Switch wires to 2.0 in. (50.8
mm) and strip 0.5 in. (12.7 mm) of insulation.

Complete assembly. See

Fit

new

switch into cavity, so that it sits in a horizontal

position (orange/white wire towards clutch lever bracket).
Properly installed, switch is captured by blocks cast into
lower housing.

Keeping splices above bracket, install lower bracket (weld
nut side down), so that lower step is positioned over
switch. Slots in upper step engage two tabs on plastic
insert.

Install shorter screw to secure front side of lower bracket
to threaded boss. Install longer rear screw. Use thru hole
in upper step of bracket to engage threaded hole in
casting.

Note lettering for proper orientation and gently push
keycap onto switch shaft.

sm00087

1. Cable strap
2. Bracket
3. Left turn signal switch

Figure 7-144. Insert Cable Strap in Switch Bracket

2011 Touring Service: Electrical 7-113

Final Instructions

See

Figure 7-144

. Insert tapered end of

new

cable strap

into round hole in turn signal switch bracket and then feed
back through using adjacent hole. Reserve oblong hole
for bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal
switch bracket.

Start screw to secure bracket inside housing.

If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)

Loop switch wires, so that spliced lengths are positioned
as shown in

Figure 7-145

Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.

Tighten screw to secure bracket inside housing.

See

Figure 7-145

. Route wire bundle to upper switch

housing below and then forward of the main wire harness
positioning conduit in channel next to angular arm of
bracket. Secure bundle to arm using

new

cable strap. Cut

any excess cable strap material.

Complete assembly. See

ASSEMBLIES, Assembly: Left Side Handlebar Switches

sm03701

1. Splices
2. Angular arm
3. Cable strap

Figure 7-145. Lower Left Handlebar Switch Housing (With

Splices) - Classic/Ultra Models

GENERAL REPAIR PROCEDURES

To better access wires and avoid damaging conduit with
radiant heating device, push conduit back and secure with
extra 7.0 in. (178 mm) cable strap in kit.

Strip 0.5 in. (12.7 mm) of insulation off switch wires. Twist
stripped ends of switch wires until all strands are tightly
coiled.

Cut dual wall heat-shrink tubing supplied in kit into 1.0 in.
(25.4 mm) segments. Slide tubing over each wire of

new

switch assembly.

NOTE

If absent from kit, obtain heat shrink tubing (Part No. 72266-
94) and two 7.0 in. (178 mm) cable straps (Part No. 10181).

See

Figure 7-146

. Matching wire colors, mate old and

new

switch wires and splice as follows:

Hold the wires so that the stripped ends cross (1).
Note that the wire on the left is on top and two-thirds
of its stripped length lies beyond the point where they
intersect. Looking at the other wire, only 1/3 of its
stripped length lies beyond the intersection point.

Holding the wires together at their juncture, start the
splice by tightly twisting the top one-third length of
the right hand wire over the left (2).

Tightly coil the remaining two-thirds of the left hand
wire around the right (3).

Solder the spliced connections.

7-114 2011 Touring Service: Electrical

NOTE

For best results, do one wire at a time.

Center the heat-shrink tubing over the soldered splices.

Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)

•

Avoid directing heat toward any fuel system com-
ponent. 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.

See

Figure 7-147

. Using the UltraTorch UT-100, Robinair

Heat Gun with heatshrink attachment or other suitable
radiant heating device, uniformly heat the heat-shrink
tubing to insulate and seal the soldered connections. Apply
heat just until the meltable sealant exudes out both ends
of the tubing and it assumes a smooth cylindrical appear-
ance.

NOTE

Electrically connected solder outside the tubing may cause a
short to ground resulting in switch failure.

Inspect the melted sealant for solder beads. Excess solder
or heat may force some solder out with the melted sealant.
Use a small needle nose pliers to remove any solder
found. Briefly heat the connection to reseal the tubing if
solder beads were removed. Use less solder or reduce
heating time or intensity when doing subsequent splices.

Cut cable strap compressing conduit and move to its ori-
ginal position.

sm03702

1. Cross stripped ends
2. Twist right wire
3. Twist left wire

Figure 7-146. Splice Switch Wires

sm00082

1. Ultra Torch UT-100
2. Robinair Heat Gun
3. Heat Shield Attachment

Figure 7-147. Radiant Heating Devices

ASSEMBLY: RIGHT SIDE HANDLEBAR
SWITCHES

If replacing lower housing switches, proceed to next step.
If replacing upper housing switches, proceed to step 8.