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Harley Davidson 2005 touring models. Service repair manual - page 29

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Left Handlebar

Main to Interconnect

Switch Controls [24]

Harness [15]

Indicator

Lamps [21]

Main to Interconnect

Harness [156]

Tachometer

Gauge [108]

Ambient

Speedometer

Temperature

Gauge [39]

Sensor [107]

Main to Interconnect

Harness [2]

Front Turn

Signals [31]

Radio [27]

Main to Interconnect

Audio to Interconnect

Harness [1]

Harness [6]

Front

Fairing Cap

Fender Tip [32]

Switches [105]

Auxiliary

Lamp [73]

Right Handlebar

Switch Controls [22]

f2238x8x

Figure 8-159. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)

8.

See Figure 8-160. Remove connectors from

spade con-

9. Feed

conduit (with orange tape) terminating in left side

tacts as follows:

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

nal connectors to mid section of inner fairing

(area

Left side:

between left and right fairing brackets). Also feed conduit

● Left speaker

terminating in left handlebar switch controls connector

● Fuel gauge and lamp

[24] to mid section.

● Cigarette lighter

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f2238x8x

Right

Left

Speaker

Voltmeter Gauge

Fuel Gauge

Speaker

and Lamp

and Lamp

Cigarette

Oil Pressure

Ambient

Lighter

Gauge and Lamp

Temperature

Gauge and Lamp

Figure 8-160. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)

10. Pull harness ground socket terminal from spade contact

INSTALLATION

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

NOTE

11. See Figure 8-160. Remove connectors from spade con-

When referencing inner fairing locations, the term “fairing

tacts as follows:

bracket” refers to either the left or right vertical support, while

Right side:

the term “support brace” refers to either the left or right hori-

● Right speaker

zontal support. References to left and right always refers to

left and right side of motorcycle.

● Voltmeter gauge and lamp

1.

Center interconnect harness on top of radio. To verify

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

proper orientation, be sure that convoluted tubing (with

speaker and voltmeter gauge connectors to mid section

anchor) of headlamp connector is on left side of motor-

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

cycle, while conduit (with anchor) of fairing cap switch

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

connector is on the right.

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

2.

Install anchors on convoluted tubing of interconnect har-

13. If present, remove connectors from spade contacts as

ness into lower outboard ears of speedometer and

follows:

tachometer brackets. See Figure 8-158.

● Oil pressure gauge and lamp

3.

If present, install connectors onto spade contacts as fol-

lows:

● Ambient temperature gauge and lamp

● Oil pressure gauge and lamp

14. Remove interconnect harness from motorcycle.

● Ambient temperature gauge and lamp

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4.

From mid section of inner fairing (area between left and

right fairing brackets), feed conduit (with orange tape)

9421

terminating in left side speaker, fuel gauge, cigarette

lighter and front turn signal connectors behind left fairing

bracket to area of left support brace.

5.

Install connectors onto spade contacts as follows:

Left side:

● Left speaker

● Fuel gauge and lamp

● Cigarette lighter; connect the orange/white wire

socket terminal to the socket spade contact, the

black wire socket terminal to the shell contact.

Anchor

6.

From mid section of inner fairing (area between left and

right fairing brackets), also feed conduit terminating in

left handlebar switch controls connector [24] behind left

Figure 8-161. Anchor Convoluted Tubing of

fairing bracket to area of left support brace.

Headlamp Connector

7.

Push harness ground socket terminal onto spade con-

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

9423

8.

From mid section of inner fairing, feed conduit (with

orange tape) terminating in right side speaker and volt-

meter gauge connectors behind right fairing bracket to

area of right support brace.

Anchor

9.

Install connectors onto spade contacts as follows:

Right side:

● Right speaker

Oval Shaped

Hole

● Voltmeter gauge and lamp

10.

From mid section of inner fairing, also feed conduit ter-

minating in main to interconnect harness connectors [2]

and [156] behind right fairing bracket to area of right sup-

port brace.

Figure 8-162. Anchor Conduit of Fairing Cap

11.

Mate pin and socket halves of the following connectors

Switch Connector

and fix positions using retaining devices, if present:

a. Main to interconnect harness connector

[2],

12-

9422

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

brace (outboard side).

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

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

brace (inboard side).

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

radio (right side).

d. Indicator lamps

[21];

10-place Multilock

(black);

above radio (between speedometer and tachometer

Cable

gauges).

Strap

e. Speedometer connector

[39];

12-place Packard

(black); back of speedometer. Slide odometer reset

switch through hole in inner fairing and install rubber

Figure 8-163. Cable Strap Convoluted Tubing, Conduit

boot.

and Connector to Fairing Bracket

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5. See Figure 8-164. Disconnect main harness from inter-

INTERCONNECT HARNESS (FLTR)

connect harness as follows:

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

REMOVAL

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

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

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

MAXI-FUSE, REMOVAL.

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

2. Place protective material on top of front fender to protect

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

paint from scratches or other damage.

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

3.

Remove the outer fairing and windshield. See Section

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

2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER

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

FAIRING, REMOVAL.

4.

Carefully cut two cable straps to free wire bundles and

6. See Figure 8-164. Disconnect handlebar switch controls

conduit from convoluted tubing of interconnect harness

from interconnect harness. Disconnect radio and radio

and allow to hang naturally. See Figure 8-166.

ground. Proceed as follows:

Main to Interconnect

Harness [1]

Left Handlebar

Radio [27]

Switch Controls [24]

Right Handlebar

Switch Controls [22]

Main to Interconnect

Harness [156]

Radio

Ground

Main to Interconnect

Harness [2]

Right Turn

Left Turn

Signal [31R]

Signal [31L]

Main to Interconnect

Harness [15]

f2269x8x

Figure 8-164. Inner Fairing Connections (FLTR)

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Instrument Nacelle

Indicator

f2219x8x

Switches [105]

Lamps [21]

Tachometer

Gauge [108]

Speedometer

Gauge [39]

Speaker

Ambient

Switch [105]

Temperature

Sensor [107]

Figure 8-165. Instrument Nacelle (Bezel Removed)

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

9.

See Figure 8-165. Draw branches of interconnect har-

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

ness (terminating in odometer reset switch and speed-

bracket.

ometer, tachometer, indicator lamps, instrument nacelle

switch and ambient temperature sensor connectors)

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

from instrument nacelle through tunnel of fairing bracket

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

to front of inner fairing. Allow the interconnect harness to

bracket.

hang along the left side of the front fender.

NOTE

10.

Remove connectors from spade contacts as follows:

Push on each handlebar connector to disengage small end

Left side:

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

connector off T-stud.

● Left speaker

● Fuel gauge and lamp (with orange tape)

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

radio (right side).

● Ambient temperature gauge and lamp

● Radio ground; single spade and socket terminal;

● Cigarette lighter

below radio (left side).

Right side:

7. Remove left side of instrument nacelle. See Section 2.30

● Right speaker

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

NACELLE, REMOVAL, steps 1-6.

● Voltmeter gauge and lamp (with orange tape)

● Oil pressure gauge and lamp

8. See Figure

8-165. Disconnect instrument nacelle

switches and ambient temperature sensor from intercon-

nect harness as follows:

11.

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

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

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

of inner fairing.

Multilock.

12.

Remove interconnect harness from motorcycle. Remove

● Ambient temperature sensor connector [107], 3-

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

place Multilock.

side) to facilitate removal.

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3.

Find branch of interconnect harness terminating in

9427a

odometer reset switch and speedometer, tachometer,

indicator lamps, instrument nacelle switch and ambient

temperature sensor connectors. Feed connectors and

conduit from front of inner fairing through tunnel of fair-

ing bracket and then out through opening at top of fairing

bracket to instrument nacelle.

4.

See Figure 8-165. Connect instrument nacelle switches

and ambient temperature sensor to interconnect har-

ness as follows:

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

Multilock.

● Ambient temperature sensor connector [107], 3-

1

2

place Multilock.

5.

See Figure 8-164. Connect handlebar switch controls to

Figure 8-166. Cable Strap Convoluted Tubing

interconnect harness. Connect radio and radio ground.

and Conduit

Proceed as follows:

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

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

INSTALLATION

bracket.

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

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

CAUTION

bracket.

To avoid chafing wires of interconnect harness, verify

NOTE

that trim strips are installed on hooks of radio bracket.

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

1.

Center convoluted tubing of interconnect harness above

radio bracket and push on each handlebar connector to

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

engage small end of slot.

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

of conduit terminating in socket terminals of cigarette

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

lighter is on left side of motorcycle. Install radio antenna

radio (right side).

cable connector

[51] at back of radio

(left side), if

removed.

● Radio ground; single spade and socket terminal;

below radio (left side).

2.

Install connectors onto spade contacts as follows:

6. See Figure 8-164. Connect main harness to intercon-

Left side:

nect harness as follows:

● Left speaker

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

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

● Fuel gauge and lamp (with orange tape)

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

● Ambient temperature gauge and lamp

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

● Cigarette lighter; connect the orange/white wire

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

socket terminal to the socket spade contact, the

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

black wire socket terminal to the shell contact.

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

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

Right side:

7.

Orient connectors as shown in Figure 8-164. Install two

● Right speaker

new cable straps outboard of radio bracket hooks to

● Voltmeter gauge and lamp (with orange tape)

secure wire bundles and conduit to convoluted tubing of

interconnect harness. Cut any excess cable strap mate-

● Oil pressure gauge and lamp

rial. See Figure 8-166.

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RADIO ANTENNA CABLE

(FLHTC/U)

Cable

Clip

Grommet

REMOVAL

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

REMOVAL, FLHT/C. For fuel injected models, see Sec-

tion 9.4 FUEL TANK (FUEL INJECTED), COMPLETE

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

Cavity

2.

Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

Tour-Pak Lights

3.

Gently pull side cover from frame downtubes (no tools

Connector [12]

required).

4.

Remove the outer fairing and windshield. See Section

Radio Antenna

2.29 UPPER FAIRING/WINDSHIELD

(FLHT/C/U),

Cable

OUTER FAIRING/WINDSHIELD, REMOVAL.

f1466a2x

5.

Remove radio antenna cable connector [51] at back of

radio (left side). See Figure 8-167. Carefully cut cable

Figure 8-168. Disconnect Tour-Pak Lights Connector

where it exits branch of main harness conduit.

6.

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

release main harness (and audio harness on FLHTCU)

Tour-Pak

Hole

Radio Antenna

from right side of steering head.

Cable Connector

7.

Carefully cut cable straps securing main harness to

frame backbone, left frame tube and luggage rack rail.

See Figure 8-170.

8.

Open Tour-Pak and proceed as follows:

FLHTC: Remove rubber mat.

Radio Antenna

Cable [51]

Grommet

Cable

Clip

f1465a2x

Figure 8-169. Feed Main Harness Thru Tour-Pak Hole

FLHTCU:

Open map pocket and remove acorn nuts

(with flat washers). Remove map pocket and molded

liner from Tour-Pak.

9. Depress external latch and remove bulb socket from left

side of Tour-Pak.

10. Rotate knurled ring in a counterclockwise direction to

separate pin and socket halves of radio antenna cable

f2238x8x

connector. Release cable from two clips at bottom of

Tour-Pak.

Figure 8-167. Remove Outer Fairing (FLHTC/U)

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11. Depress button and separate pin and socket halves of

Tour-Pak lights connector [12], 3-place Multilock, inside

A = Anchored

Tour-Pak. See Figure 8-168.

Frame

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

Backbone

ness conduit.

1

13. Pull Tour-Pak lights and radio antenna cable connectors

through hole at front of Tour-Pak. See Figure 8-169.

2 A

14. Carefully cut radio antenna cable where it exits main

harness conduit.

3 A

INSTALLATION

1. Place new radio antenna cable on motorcycle following

original routing. Note that the cable follows the branches

4 A

of the main harness (and audio harness on FLHTCU)

routed to the rear left side of the motorcycle.

NOTE

Specifically, from the front of the inner fairing, the radio

5 A

antenna cable is routed under the fairing cap where it passes

through a P-clamp on the right side of the steering head. The

Saddlebag

6

Guard

cable then runs along the right side of the frame backbone,

where it crosses to the left side at the main harness anchor in

the center of the frame backbone. From this point, the cable

follows the left side of the frame backbone, runs along the

7

inboard side of the upper frame tube and then continues

down the luggage rack rail where it passes through the hole

f2225x8x

at the front of the Tour-Pak.

1

Captures main harness, cruise roll-off switch conduit,

2.

Feed Tour-Pak lights and radio antenna cable connec-

audio harness (FLHTCUI only) and frame backbone.

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

2

Captures main harness and audio harness

(FLHTCUI

ture conduit in grommet. Install grommet in hole with the

only). ANCHORED.

larger OD facing inside.

3

4

Captures main harness and audio harness

(FLHTCUI

only). ANCHORED.

3.

Mate pin and socket halves of Tour-Pak lights connector

5

Captures main harness, audio harness (FLHTCUI only),

[12], 3-place Multilock, and tuck into cavity inside Tour-

fuel vapor vent tube and console pod or instrument

Pak. See Figure 8-168.

console conduit. ANCHORED.

6

Captures main harness, audio harness (FLHTCUI only),

4.

Rotate knurled ring in a clockwise direction to mate pin

console pod or instrument console conduit and upper

frame tube.

and socket halves of radio antenna cable connector.

Capture cable in two clips at bottom of Tour-Pak.

7

Captures main harness, audio harness (FLHTCUI only),

console pod conduit (FLHTCUI only) and upper frame

tube.

5.

Install bulb socket on left side of Tour-Pak.

6.

Proceed as follows:

Figure 8-170. Install Cable Straps

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

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

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

9.

At front of top engine stabilizer bracket, install new 14

Close Tour-Pak.

inch cable strap capturing frame backbone, radio

antenna cable, main harness and audio harness (if

7.

At front of inner fairing, connect radio antenna cable

present). Tighten cable strap, but leave loose enough so

connector [51] to back of radio. See Figure 8-167.

that one finger can be inserted between strap and frame

backbone. Do not overtighten. Cut any excess cable

8.

On right side of motorcycle, capture radio antenna cable,

strap material.

main harness and audio harness (if present) in P-clamp.

Install ground wire ring terminal on screw and fasten P-

10.

Install remaining cables straps as shown in Figure 8-

clamp to right side of steering head.

170.

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RADIO ANTENNA CABLE (FLTR)

1

9425

REMOVAL

1.

Remove fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,

FLTRI.

2.

Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

3.

Gently pull side cover from frame downtubes (no tools

required).

4.

Remove the outer fairing and windshield. See Section

2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER

2

FAIRING, REMOVAL.

5.

Remove radio antenna cable connector [51] at back of

Figure 8-172. Capture Radio Antenna Cable

radio (left side). See Figure 8-171. Carefully cut cable

where it exits branch of main harness conduit.

9.

Carefully cut cable strap to release radio antenna cable

6.

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

release main harness bundle from right side of steering

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

valve mounting bracket). Cut cable strap to release radio

head.

antenna cable from slotted hole in rear fender support.

7.

Carefully cut cable straps securing main harness to

See Figure 8-172.

frame backbone and left frame tube. See Figure 8-173.

10.

At bottom of radio antenna bracket, rotate knurled ring to

separate pin and socket halves of radio antenna cable

8.

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

connector [51].

to remove passenger seat strap and saddlebag front

mounting bracket. Remove Phillips screw and chrome

11.

Draw radio antenna cable forward to area of fuse block

frame tube cover.

bracket. Carefully cut cable where it exits branch of main

harness conduit.

Radio Antenna

INSTALLATION

Cable [51]

1.

Place new radio antenna cable on motorcycle following

original routing. Note that the cable follows the branches

of the main harness routed to the rear left side of the

motorcycle.

NOTE

Specifically, from the front of the inner fairing, the radio

antenna cable is routed through an opening on the right side

of the fairing bracket where it then passes through a P-clamp

on the right side of the steering head. The cable runs rear-

ward along the right side of the frame backbone, where it

crosses to the left side at the main harness anchor in the

center of the frame backbone. From this point, the cable fol-

lows the left side of the frame backbone, runs along the

inboard side of the upper frame tube and then down to the

radio antenna bracket.

2.

Feed radio antenna cable and connector rearward fol-

lowing inboard side of upper frame tube. With the 3-

f2230x2x

place Multilock connector (unused) positioned about as

far rearward as the rear shock air valve, install new

Figure 8-171. Remove Outer Fairing

(FLTR)

cable strap to secure radio antenna cable to shoulder of

2005 Touring: Electrical

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upper frame tube (just in front of air valve mounting

bracket). Using slotted hole, install new cable strap to

A = Anchored

secure radio antenna cable to rear fender support. See

Figure 8-172.

Frame

Backbone

3.

At bottom of radio antenna bracket, rotate knurled ring to

1

mate pin and socket halves of radio antenna cable con-

nector [51].

4.

Install chrome frame tube cover on frame tube. Install

2 A

Phillips screw. Install bolt

(with flat washer) to fasten

saddlebag front mounting bracket and passenger seat

strap to chrome frame tube cover.

5.

At front of inner fairing, connect radio antenna cable

3 A

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

171.

6.

On right side of motorcycle, capture radio antenna cable

4 A

and main harness in P-clamp. Install ground wire ring

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

steering head.

7.

At front of top engine stabilizer bracket, install new 14

inch cable strap capturing frame backbone, radio

5 A

antenna cable and main harness. Tighten cable strap,

but leave loose enough so that one finger can be

Saddlebag

inserted between strap and frame backbone. Do not

6

Guard

overtighten. Cut any excess cable strap material.

8.

Install remaining cables straps as shown in Figure 8-

7

170.

9.

Install the outer fairing and windshield. See Section 2.30

f2225x8x

UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR-

ING, INSTALLATION.

1

Captures main

harness, cruise roll-off switch conduit,

10.

Align barbed studs in left side cover with grommets in

audio harness (FLHTCUI only) and frame backbone.

frame downtubes and push firmly into place (no tools

2

Captures main harness and audio harness

(FLHTCUI

only). ANCHORED.

required).

3

4

Captures main harness and audio harness

(FLHTCUI

11.

Install left side saddlebag. See Section 2.25 SADDLE-

only). ANCHORED.

BAG, INSTALLATION.

5

Captures main harness, audio harness (FLHTCUI only),

fuel vapor vent tube and console pod or instrument

12.

Install fuel tank. See Section 9.4 FUEL TANK (FUEL

console conduit. ANCHORED.

6

Captures main harness, audio harness (FLHTCUI only),

INJECTED), INSTALLATION

(AFTER COMPLETE

console pod or instrument console conduit and upper

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

frame tube.

7

Captures main harness, audio harness (FLHTCUI only),

console pod conduit (FLHTCUI only) and upper frame

tube.

Figure 8-173. Install Cable Straps

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AUDIO HARNESS (FLHTCU)

Console Pod

Connector [53]

REMOVAL

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

REMOVAL, FLHT/C. For fuel injected models, see Sec-

tion 9.4 FUEL TANK (FUEL INJECTED), COMPLETE

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

2.

Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

3.

Gently pull side cover from frame downtubes (no tools

required).

4.

Repeat steps 2 and 3 on left side of motorcycle.

5.

Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD

(FLHT/C/U),

OUTER FAIRING/WINDSHIELD, REMOVAL.

f2192x8x

6.

See Figure 8-174. Disconnect pin and socket halves of

Figure 8-175. Disconnect Console Pod Connector

the following connectors:

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

(right side).

7.

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

release main harness and audio harness from right side

b. Audio to interconnect harness connector

[6],

3-

of steering head.

place Deutsch (black); back of radio (right side).

8.

Carefully pull audio harness rearward under right side of

c. Radio connector [28], 23-place Amp (gray); back of

fairing cap allowing conduit and connectors to hang over

radio (left side).

top of engine guard.

9.

Carefully cut cable straps securing audio harness to

Audio to

frame backbone, left and right frame tubes, and luggage

Interconnect Harness [6]

rack rails. See Figure 8-177. Carefully cut cable straps

securing audio harness to main harness, if present.

CB Antenna

Radio [28]

10.

Remove flange nut (10 mm) from right side ground stud

Cable [50]

on upper frame crossmember. Remove audio harness

ground ring terminal.

11.

Release console pod connector [53],

12-place Mini-

Deutsch, from attachment clip anchored in hole at rear

of battery box. See Figure

8-175. Depress external

latches and use a rocking motion to separate pin and

socket halves.

12.

Remove trim

ring and gently pull on wire harness to

draw rear right speaker/passenger controls connector

[41], 6-place Mini-Deutsch, out of speaker box. Depress

external latch and use a rocking motion to separate pin

and socket halves.

13.

Open Tour-Pak. Open map pocket and remove acorn

nuts. Remove map pocket and molded liner from Tour-

Pak.

f2238x8x

14.

Separate pin and socket halves of CB antenna cable

connector [50]. Release cable from clip at bottom of

Figure 8-174.

Audio Harness Connectors

Tour-Pak. See Figure 8-176.

2005 Touring: Electrical

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2.

See Figure 8-174. Standing at front of motorcycle, mate

pin and socket halves of the following wire harness con-

Grommet

nectors:

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

Cable

(right side).

Clip

b. Audio to interconnect harness connector

[6],

3-

place Deutsch (black); back of radio (right side).

c. Radio connector [28], 23-place Amp (gray); back of

radio (left side).

3.

On right side of motorcycle, capture audio harness and

main harness in P-clamp. Install ground wire ring termi-

nal on screw and fasten P-clamp to right side of steering

head.

4.

Install audio harness ground ring terminal onto right side

ground stud on upper frame crossmember. Install flange

CB Antenna

nut (10 mm) and tighten to 50-90 in-lbs (5.7-10.2 Nm).

Cable Connector

f1467b2x

5.

Mate pin and socket halves of console pod connector

[53],

12-place Mini-Deutsch. Install connector onto

Figure 8-176. Disconnect CB Antenna Cable Connector

attachment clip anchored in hole at rear of battery box.

See Figure 8-175.

15. Pull right side grommet into Tour-Pak and remove from

6.

Mate pin and socket housings of rear right speaker/pas-

CB antenna cable. Feed CB antenna cable through hole

senger controls connector [41], 6-place Mini-Deutsch.

at front of Tour-Pak.

Feed connector back up into speaker box pressing trim

ring into hole.

16. Moving to opposite side of motorcycle, remove trim ring

and gently pull on wire harness to draw rear left speaker/

7.

Pass CB antenna cable connector [50] through hole at

passenger controls connector [42], 6-place Mini-Deut-

front of Tour-Pak. Capture cable in grommet. Install

sch, out of speaker box. Depress external latch and use

grommet in hole with the larger OD facing inside. See

a rocking motion to separate pin and socket halves.

Figure 8-176.

17. Release rear headset receptacle from bracket at bottom

8.

Mate pin and socket halves of CB antenna cable con-

of left side speaker box. Release spring from hole in

nector. Capture antenna cable in clip at bottom of Tour-

receptacle wire jacket.

Pak.

18. Remove audio harness from motorcycle.

9.

Moving to opposite side of motorcycle, mate pin and

socket housings of rear left speaker/passenger controls

connector [42], 6-place Mini-Deutsch. Feed connector

INSTALLATION

back up into speaker box pressing trim ring into hole.

10.

Attach spring to rear headset receptacle using hole in

1.

Place new audio harness on motorcycle following origi-

wire jacket. Capture headset receptacle in bracket at

nal routing. Note that the audio harness follows the

bottom of left side speaker box.

branches of the main harness as it is routed to the rear

left and right sides of the motorcycle.

11.

At front of top engine stabilizer bracket, install new 14

inch cable strap capturing frame backbone, audio har-

NOTE

ness and main harness. Tighten cable strap, but leave

loose enough so that one finger can be inserted

Specifically, from the front of the inner fairing, the audio har-

between strap and frame backbone. Do not over-

ness is routed under the fairing cap where it passes through

tighten. Cut any excess cable strap material.

a P-clamp on the right side of the steering head. The harness

then runs along the right side of the frame backbone, where

12.

Install remaining cables straps as shown in Figure 8-

a branch crosses to the left side at the main harness anchor

177.

in the center of the frame backbone. From this point, each

branch follows its respective side of the frame backbone, run-

13.

Install the outer fairing and windshield. See Section 2.29

ning along the inboard side of the upper frame tubes and

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

then down the luggage rack rails.

FAIRING/WINDSHIELD, INSTALLATION.

8-144

2005 Touring: Electrical

HOME

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

frame downtubes and push firmly into place (no tools

A = Anchored

required).

Frame

15. Install right side saddlebag. See Section 2.25 SADDLE-

Backbone

1

BAG, INSTALLATION.

16. Repeat steps 14 and 15 on left side of motorcycle.

17. Install fuel tank. For carbureted models, see Section 4.7

2 A

FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHT/C. For fuel injected

models, see Section

9.4 FUEL TANK

(FUEL

INJECTED), INSTALLATION

(AFTER COMPLETE

8 A

3 A

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

9 A

4 A

10 A

5 A

Saddlebag

11

6

Guard

12

7

f2225x8x

1

Captures main harness, cruise roll-off switch conduit,

audio harness (FLHTCUI only) and frame backbone.

2

Captures main harness and audio harness

(FLHTCUI

only). ANCHORED.

3

4

5 Captures main harness, audio harness (FLHTCUI only),

EFI/ignition harness, and conduit to fuel tank harness (all

models except FLHR/C/S). ANCHORED.

6

7

Captures audio harness (FLHTCUI only) and upper frame

tube.

8

9

Captures main harness and audio harness

(FLHTCUI

only). ANCHORED.

10

Captures main harness, audio harness (FLHTCUI only),

fuel vapor vent tube and console pod or instrument

console conduit. ANCHORED.

11

Captures main harness, audio harness (FLHTCUI only),

console pod or instrument console conduit and upper

frame tube.

12

Captures main harness, audio harness (FLHTCUI only),

console pod conduit (FLHTCUI only) and upper frame

tube.

Figure 8-177. Install Cable Straps

2005 Touring: Electrical

8-145

HOME

CB ANTENNA CABLE (FLHTCU)

Grommet

REMOVAL

Cable

Clip

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

REMOVAL, FLHT/C. For fuel injected models, see Sec-

tion 9.4 FUEL TANK (FUEL INJECTED), COMPLETE

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

2.

Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

3.

Gently pull side cover from frame downtubes (no tools

required).

4.

Remove the outer fairing and windshield. See Section

2.29 UPPER FAIRING/WINDSHIELD

(FLHT/C/U),

OUTER FAIRING/WINDSHIELD, REMOVAL.

CB Antenna

5.

Locate CB antenna cable connector [50] at back of radio

Cable Connector

f1467b2x

(right side). Rotate knurled ring in a counterclockwise

direction to disconnect. See Figure 8-178. Carefully cut

cable where it exits audio harness conduit.

Figure 8-179. CB Antenna Cable Connector

(Tour-Pak)

6.

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

release main harness and audio harness from right side

of steering head.

8.

Open Tour-Pak. Open map pocket and remove acorn

7.

Carefully cut cable straps securing audio harness to

nuts

(with flat washers). Remove map pocket and

frame backbone, right frame tube and luggage rack rail.

molded liner from Tour-Pak.

See Figure 8-181. Carefully cut cable straps securing

9.

Separate pin and socket halves of CB antenna cable

audio harness to main harness, if present.

connector [50]. Release cable from clip at bottom of

Tour-Pak. See Figure 8-179.

10. Pull right side grommet into Tour-Pak and remove from

CB Antenna

Cable [50]

CB antenna cable. Feed CB antenna cable through hole

at front of Tour-Pak.

11. Carefully cut CB antenna cable where it exits branch of

audio harness conduit.

INSTALLATION

1.

Place new CB antenna cable on motorcycle following

original routing. Note that the cable follows the branches

of the main harness and audio harness routed to the

rear right side of the motorcycle.

NOTE

Specifically, from the front of the inner fairing, the CB

antenna cable is routed under the fairing cap where it passes

through a P-clamp on the right side of the steering head.

f2238x8x

From this point, the cable follows the right side of the frame

backbone, runs along the inboard side of the upper frame

Figure 8-178. CB Antenna Cable Connector

tube and then continues down the luggage rack rail where it

(Inner Fairing)

passes through the hole at the front of the Tour-Pak.

8-146

2005 Touring: Electrical

HOME

2.

Pass CB antenna cable connector [50] through hole at

front of Tour-Pak. Capture cable in grommet. Install

A = Anchored

grommet in hole with the larger OD facing inside. See

Figure 8-179.

Frame

Backbone

3.

Mate pin and socket halves of CB antenna cable con-

1

nector. Capture antenna cable in clip at bottom of Tour-

Pak.

2 A

4.

Install two new cable straps to secure CB antenna cable

to rear right speaker/passenger controls conduit and lug-

gage rack rail. See Figure 8-180.

5.

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

3 A

secure using acorn nuts (with flat washers). Close Tour-

Pak.

6.

At front of inner fairing, rotate knurled ring to connect CB

4 A

antenna cable connector [50] to back of radio. See Fig-

ure 8-178.

7.

On right side of motorcycle, capture CB antenna cable,

audio harness and main harness in P-clamp. Install

ground wire ring terminal on screw and fasten P-clamp

5 A

to right side of steering head.

Saddlebag

6

Guard

8.

At front of top engine stabilizer bracket, install new 14

inch cable strap capturing frame backbone, CB antenna

cable, audio harness and main harness. Tighten cable

strap, but leave loose enough so that one finger can be

inserted between strap and frame backbone. Do not

7

overtighten. Cut any excess cable strap material.

f2225x8x

9.

Install remaining cables straps as shown in Figure 8-

181.

1

Captures main harness, cruise roll-off switch conduit,

audio harness (FLHTCUI only) and frame backbone.

10.

Install the outer fairing and windshield. See Section 2.29

2

Captures main harness and audio harness

(FLHTCUI

only). ANCHORED.

UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER

3

4

5 Captures main harness, audio harness (FLHTCUI only),

FAIRING/WINDSHIELD, INSTALLATION.

EFI/ignition harness, and conduit to fuel tank harness (all

models except FLHR/C/S). ANCHORED.

6

7

Captures audio harness (FLHTCUI only) and upper frame

tube.

9426

Figure 8-181. Install Cable Straps

11. Align barbed studs in right side cover with grommets in

frame downtubes and push firmly into place (no tools

1

required).

12. Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

2

13. Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

COMPLETE REMOVAL), FLHT/C. For fuel injected

models, see Section

9.4 FUEL TANK

(FUEL

INJECTED), INSTALLATION

(AFTER COMPLETE

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

Figure 8-180. Secure CB Antenna Cable

2005 Touring: Electrical

8-147

HOME

IGNITION HARNESS

f1847x8x

(CARBURETED)

REMOVAL

1.

Remove fuel tank. See Section 4.7 FUEL TANK (CAR-

BURETED), COMPLETE REMOVAL, FLHT/C or

1

FLHR/S.

2.

Unthread bolt and remove battery positive cable (red)

from battery positive

(+) terminal.

(Battery negative

cable already removed under FUEL TANK, COMPLETE

REMOVAL.)

3.

Using a T40 TORX drive head, loosen bolt to move lip of

hold-down clamp off edge of battery. Remove battery

from battery box.

2

4.

Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

5.

Gently pull side cover from frame downtubes (no tools

1.

Vehicle Speed Sensor [65]

required).

2.

P&A Security Siren [142]

6.

Carefully cut cable straps to free ignition harness from

Figure 8-183. Electrical Bracket (Inboard Side)

right side of frame backbone, upper frame tube and

other wire harness bundles. See Figure 8-186.

7.

Remove ignition coil connector [83] and manifold abso-

8.

Remove ignition control module connector [10]. Depress

lute pressure sensor connector [80]. Pull external latch

external latches and use a rocking motion to separate

outward and use rocking motion to separate pin and

pin and socket halves. See Figure 8-182.

socket halves. Draw conduit and connectors to right side

of motorcycle as they are disconnected.

9.

Gently pull on data link connector [91] to disengage from

arms on electrical bracket.

10.

Pull main harness connector [8] from slot in electrical

Main Harness [8]

bracket. Depress external latches and use a rocking

Data Link [91]

motion to separate pin and socket halves.

11.

Remove two flange nuts to release electrical bracket

from studs on side of battery box.

12.

On inboard side of electrical bracket, disconnect vehicle

speed sensor connector [65]. Depress button on socket

housing and pull apart pin and socket halves. See Fig-

ure 8-183.

CAUTION

Damage to wires can result in electrical problems. Be

sure that rubber boot is present on threaded end of bat-

tery box TORX screw. Replace rubber boot if absent or

damaged. See Figure 8-184.

13. Note that ignition harness conduit runs forward of the

Ignition Control

front battery box TORX screw. Pull conduit to the rear of

Module [10]

f2191x8x

the screw, and then draw connectors and conduit down

right side of frame backbone into battery box.

Figure 8-182. Electrical Bracket (Under Right Side Cover)

8-148

2005 Touring: Electrical

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8321

Vehicle Speed

Ignition

Control Module

Sensor [65B]

[10B]

Rubber

Boot

Main Harness

[8A]

Figure 8-184. Remove Ignition Harness From Vehicle

14. Pull connectors and conduit out through opening at side

of battery box to remove ignition harness from motorcy-

cle.

Data Link

[91A]

INSTALLATION

1. Locate end of ignition harness terminating in two con-

nectors. See Figure 8-185.

2. Standing on right side of motorcycle, carefully feed con-

nectors and conduit through opening into battery box.

Pull up on harness and tuck conduit into space in front of

the battery box TORX screw.

CAUTION

Damage to wires can result in electrical problems. Be

sure that rubber boot is present on threaded end of bat-

tery box TORX screw. Replace rubber boot if absent or

damaged. See Figure 8-184.

3. Draw connectors and conduit up along right side of

frame backbone just below the main harness bundle.

4. Loosely install new cable straps to secure ignition har-

ness to right side of frame backbone, upper frame tube

and other wire harness bundles. See Figure 8-186.

Manifold Absolute

5. Feed ignition coil connector over the top engine stabi-

Pressure

lizer link to left side of motorcycle. Install ignition coil

Sensor [80B]

connector [83] onto left side of ignition coil.

6. Install manifold absolute pressure sensor connector [80].

7.

Returning to electrical bracket, mate pin and socket

Ignition

halves of vehicle speed sensor connector [65]. Route

Coil [83B]

siren and vehicle speed sensor connectors and conduit

on inboard side of electrical bracket as shown in Figure

f2226x8x

8-183.

Figure 8-185. Ignition Wire Harness Connectors

2005 Touring: Electrical

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