Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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340

CHAPTER EIGHT

6. Separate the field coil (B, Figure 70) from the

solenoid housing (C).

7. Remove the end cap screws, washers and O-rings

(A, Figure 71). Then remove the end cap (B).

8. Pull the brush holder (A, Figure 72) away from

the commutator and remove the armature (B) from

the field coil assembly.

9. Remove the two field coil brushes from the

brush holder (Figure 73).

10. Clean all grease, dirt and carbon from the arma-

ture, field coil assembly and end covers.

CAUTION

Be extremely careful when selecting a

solvent to clean the electrical compo-

nents. Do not immerse any of the wire

windings in solvent, because the insu-

lation may be damaged. Wipe the

windings with a cloth lightly moist-

ened with solvent, then allow the solu-

tion to dry thoroughly.

11. To service the drive housing assembly, refer to

Drive Housing Disassembly/Inspection/Assembly

in this chapter.

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ELECTRICAL SYSTEM

341

12. To service the solenoid housing, refer to Sole-

noid Housing Disassembly/Inspection/Assembly in

this chapter.

Inspection

1. Measure the length of each brush with a vernier

caliper (Figure 74). If the length is less than the

minimum specified in Table 4, replace all of the

brushes as a set. See Figure 75 for the field coil and

Figure 76 for the brush holder.

NOTE

The field coil brushes (Figure 75) are

soldered in position. To replace, un-

solder the brushes by heating their

joints with a soldering gun, then pull

them out with a pair of pliers. Position

the new brushes and solder in place

with rosin core solder—do not use

acid core solder.

2. Inspect the commutator (A, Figure 77). The

mica should be below the surface of the copper

commutator segments (Figure 78). If the commuta-

tor bars are worn to the same level as the mica insu-

lation, have the commutator serviced by a

dealership or electrical repair shop.

3. Inspect the commutator copper segments for dis-

coloration. If the commutator segments are rough,

Good

discolored or worn, have the commutator serviced

by a dealership or electrical repair shop.

4. Measure the outer diameter of the commutator

with a vernier caliper (Figure 79). Replace the ar-

Worn

mature if worn to the service limit listed in Table

5. Use an ohmmeter to perform the following:

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342

CHAPTER EIGHT

Ohmmeter

Starter terminal

Field frame

Ohmmeter

Field frame

a. Check for continuity between the commuta-

tor bars (Figure 80); there must be continuity

between pairs of bars.

b. Check for continuity between any commuta-

Insulated

tor bar and the shaft (Figure 81). There must

brush

be no continuity.

holders

c. If the unit fails either of these tests, replace

the armature.

6. Use an ohmmeter to perform the following:

a. Check for continuity between the starter cable

terminal and each field frame brush (Figure

82); there must be continuity.

b. Check for continuity between the field frame

housing and each field frame brush (Figure

83); there must be no continuity.

c. If the unit fails either of these tests, replace

the field frame assembly.

Test leads

7. Use an ohmmeter and check for continuity be-

Brush holder plate

tween the brush holder plate and each brush holder

(Figure 84); there must be no continuity. If the unit

fails this test, replace the brush holder plate.

8. Service the armature bearings as follows:

a. Check the bearings (B, Figure 77) on the arma-

ture shaft. Replace worn or damaged bearings.

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ELECTRICAL SYSTEM

343

NOTE

The armature shaft bearings have dif-

ferent part numbers. Identify the old

bearings before removing them.

b. Check the bearing bores in the end cover and

solenoid housing. Replace the cover or hous-

ing if the area is worn or cracked.

Assembly

Refer to Figure 66.

1. If serviced, assemble the drive housing as de-

scribed in this chapter.

2. If serviced, assemble the solenoid housing as de-

scribed in this chapter.

3. Lubricate the armature bearings (B, Figure 77)

with high-temperature grease.

4. Install two new O-rings onto the field coil shoul-

ders (Figure 85).

5. Install the two field coil brushes into the brush

plate holders (Figure 86).

6. Install the armature partially through the field

coil as shown in Figure 72. Then pull the brushes

back and push the armature forward so that when

released, all of the brushes contact the commutator

as shown in Figure 87 and Figure 88.

7. Install the end cap (Figure 89) and the two

screws, washers and O-rings. Tighten the screws se-

curely.

8. Align the field coil (A, Figure 90) with the sole-

noid housing (B) and assemble both housings. Hold

the assembly together while installing the drive

housing in Step 9.

9. Align the drive housing (Figure 91) with the

field coil and solenoid housing assembly and install

it. Install the two drive housing screws and

lockwashers (Figure 68) and tighten securely.

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344

CHAPTER EIGHT

10. Install the two through bolts, washers and

O-rings (Figure 67) and tighten securely.

11. Reconnect the C terminal field wire (C, Figure

90) at the solenoid housing.

Drive Housing

Disassembly/Inspection/Assembly

The drive housing was removed during starter

disassembly.

1. Remove the return spring (A, Figure 92), ball,

clutch shaft (B), and drive spring (Figure 93) from

the drive assembly.

2. Remove the idler gear (Figure 94) from the

drive housing.

3. Remove the idler gear bearing and cage assem-

bly (A, Figure 95). There are five individual bear-

ing rollers (Figure 96).

4. Remove the drive assembly (B, Figure 95).

5. Replace the drive housing O-ring (Figure 97) if

worn or damaged. Lubricate the O-ring with high

temperature grease.

6. Inspect the idler gear bearing and cage assembly

(Figure 96) for worn or damaged parts.

CAUTION

The drive assembly (Figure 98) is a

sealed unit. Do not clean or soak it in

any type of solvent.

7. Inspect the drive assembly and its bearings (Fig-

ure 98) for worn or damaged parts. If the bearings

are worn or damaged, replace the drive assembly

and bearings as a set.

8. Assemble the drive housing by reversing these

steps, while noting the following.

9. Lubricate the following components with high

temperature grease:

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ELECTRICAL SYSTEM

345

STARTER SOLENOID

1. Solenoid housing

5. Clip

2. Plunger

6. Lockwasher

3. Gasket

7. Bolt

4. Cover

a. Idler gear bearing and cage assembly (Figure

96).

b. Drive housing O-ring and shaft (Figure 97).

c. Drive assembly (Figure 98).

d. Clutch shaft, drive spring, return spring, and

ball.

10. Install the idler gear bearing and cage assembly

so that the open side of the cage (A, Figure 95)

faces toward the solenoid housing.

Solenoid Housing

Disassembly/Inspection/Assembly

1. Remove the solenoid housing (Figure 99) as de-

scribed during starter disassembly.

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346

CHAPTER EIGHT

2. Remove the screws, washers and clip securing

the end cover to the solenoid housing. Then remove

100

the end cover (Figure 100) and gasket.

3. Remove the plunger assembly (Figure 101).

4. Inspect the plunger (Figure 102) for scoring,

deep wear marks or other damage.

5. Inspect the solenoid housing (Figure 103) for

wear, cracks or other damage.

6. The solenoid housing is a separate assembly

and cannot be serviced. If any part is defective,

the solenoid housing must be replaced as an as-

sembly.

7. Assemble the solenoid housing by reversing

these steps. Lubricate the solenoid plunger with

101

high temperature grease.

LIGHTING SYSTEM

The lighting system consists of a headlight, tail-

light/brake light combination and turn signals.

Always use the correct wattage bulb. The use of

a larger wattage bulb will give a dim light and a

smaller wattage bulb will burn out prematurely.

Table 5 lists replacement bulbs.

Headlight Bulb Replacement

102

Refer to Figure 104.

CAUTION

All models are equipped with a

quartz-halogen bulb. Do not touch

the bulb glass. Traces of oil on the

bulb will drastically reduce the life

of the bulb. Clean all traces of oil

from the bulb glass with a cloth

moistened in alcohol or lacquer

thinner.

WARNING

103

If the headlight has just burned out or

been turned off it will be hot. To avoid

burned fingers, do not touch the bulb.

Allow the bulb to cool prior to re-

moval.

1. Loosen the pinch screw (A, Figure 105) and re-

move the trim bezel (B).

2. Pull straight out and disconnect the electrical

connector from the bulb (Figure 106) and remove

the headlight assembly.

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ELECTRICAL SYSTEM

347

104

HEADLIGHT

Plug (all models except

FXDWG)

Nut (all models except

FXDWG)

Lockwasher (all

models except

FXDWG)

Washer (all models

except FXDWG)

Bracket (all models

except FXDWG)

Trim (all models except

FXDWG)

Bolt

Housing (all models

except FXDWG)

Housing (FXDWG

models)

10.

Washer (FXDWG

models)

11.

Mounting block

(FXDWG models)

12.

Washer (FXDWG

models)

13.

Lockwasher (FXDWG

models)

14.

Nut (FXDWG models)

15.

Mounting bracket

(FXDWG models)

16.

Mounting ring

17.

Rubber cover

18.

Bulb

19.

Lens

20.

Trim bezel

21.

Nut

22.

Connector

105

106

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348

CHAPTER EIGHT

3. Remove the rubber cover (Figure 107) from the

back of the headlight lens. Check the rubber boot

107

for tears or deterioration; replace if necessary.

4. Unhook the light bulb retaining clip (Figure

108) and pivot it out of the way.

5. Remove the blown bulb (Figure 109).

6. Align the tangs on the new bulb with the

notches in the headlight lens and install the bulb.

7. Securely hook the retaining clip onto the bulb

(Figure 108).

8. Position the rubber cover so that the TOP mark

on the boot is positioned at the top of the headlight

lens. Install the rubber cover

(Figure 107) and

make sure it is correctly seated against the bulb and

108

the headlight lens.

9. Correctly align the electrical plug terminals with

the bulb

(Figure

106) and connect it. Push it

straight on until it bottoms on the bulb and the rub-

ber cover.

10. Check headlight operation.

11. Insert the lens into the headlight housing and

seat it correctly.

12. Install the trim bezel onto the headlight lens

and housing.

13. Securely tighten the pinch screw.

14. Check headlight adjustment as described in this

chapter.

109

Headlight Adjustment

1. Park the motorcycle on a level surface approxi-

mately 25 ft. (7.6 m) from the wall (Figure 110).

2. Check tire inflation pressure, and adjust if neces-

sary as described in Chapter Three.

3. Draw a horizontal line on the wall that is 35 in.

(0.9 m) above the floor.

4. Have a rider sit on the seat.

5. Aim the headlight at the wall and turn on the

headlight. Switch the headlight to the high beam.

a. Remove the plug (Figure 111) from the top of

The front wheel must be pointing straight ahead.

the headlight housing.

6. Check the headlight beam alignment. The broad,

b. Loosen the headlight clamp nut (Figure 112).

flat pattern of light (main beam of light) must be

c. Tilt the headlight assembly up or down to ad-

centered on the horizontal line (equal area of light

just the beam vertically.

above and below line).

d. Turn the assembly to the left or right sides to

7. Now check the headlight beam lateral align-

adjust the beam horizontally.

ment. With the headlight beam pointed straight

e. When the beam is properly adjusted, tighten

ahead (centered), there must be an equal area of

the headlight adjust nut securely.

light to the left and right of center.

f. Push the plug into the headlight housing.

8A. On models except FXDWG, if the beam is incor-

8B. On FXDWG models, if the beam is incorrect as

rect as described in Step 6 or Step 7, adjust as follows.

described in Step 6 or Step 7, adjust as follows.

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ELECTRICAL SYSTEM

349

110

HEADLIGHT ADJUSTMENT

35 in.

(0.9 m)

25 ft.

(7.6 m)

a. Loosen the vertical adjust bolt at the base of

111

the headlight unit.

b. Tilt the headlight assembly up or down to adjust

the beam vertically. Tighten the bolt securely.

c. Loosen the horizontal adjust bolt at the base

of the steering stem lower bracket.

d. Turn the assembly left or right to adjust the

beam horizontally. Tighten the bolt securely.

Taillight/Brake Light Replacement

Refer to Figure 113.

1. Remove the screws securing the lens (Figure

114).

112

2. Pull the lens off the base and disconnect the elec-

trical connector (Figure 115).

3. Pull the bulb/socket assembly (Figure 116) out

from the backside of the lens.

4. Rotate the bulb and remove it from the socket as-

sembly (Figure 117).

5. Install a new bulb, then install the socket assem-

bly into the lens.

6. Connect the electrical connector (Figure 115)

and install the lens onto the base.

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350

CHAPTER EIGHT

113

TAILLIGHT/BRAKE LIGHT

114

115

1. Screw

2. Lens

3. Bulb

4. Socket/harness

5. Screw

6. Circuit board/cover

assembly

7. Base

8. Cage nut

7. Install the screws and tighten securely. Do not

overtighten the screws as the lens may crack.

116

8. To replace the base, perform the following:

a. From underneath the rear fender, disconnect

the wiring harness from the backside of the

base.

b. Remove the screw securing the printed circuit

board and base

(Figure

118) to the rear

fender.

c. Remove the base.

Turn Signal Light Replacement

117

1A. On 1999-2000 models, remove the screws se-

curing the lens and remove the lens.

1B. On 2001-on models, carefully pry the lens (Fig-

ure 119) from the base.

2. Push in on the bulb, rotate it and remove it.

3. Install a new bulb and lens.

4. On 1999-2000 models, install the screws and

tighten securely. Do not overtighten the screws as

the lens may crack.

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ELECTRICAL SYSTEM

351

118

119

120

Switch

Red/Black

Red

Red/Gray

Position

Off

•

Acc.

•

Ignition

•

SWITCHES

1. Check the battery as described under Battery in

this chapter; if necessary, charge or replace the battery.

Testing

2. Disconnect the negative battery cable (see this

chapter) before checking the continuity of any

Test switches for continuity by using an ohmme-

switch.

ter (see Chapter One) or a self-powered test light at

3. Detach all connectors located between the

the switch connector plug and operating the switch

switch and the electrical circuit.

in each of its operating positions. Compare these re-

sults with the switch operating diagrams included in

CAUTION

the wiring diagrams at the end of the manual. For

Do not attempt to start the engine with

example, Figure 120 shows a continuity diagram

the battery disconnected.

for the ignition switch. It shows which terminals

should show continuity when the switch is in a

4. When separating two connectors, pull on the

given position.

connector housings and not the wires.

When the ignition switch is in the IGNITION posi-

5. After locating a defective circuit, check the con-

tion, there should be continuity between the

nectors to make sure they are clean and properly

red/black, the red and red/gray terminals. The line on

connected. Check all wires going into a connector

the continuity diagram indicates this. An ohmmeter

housing to make sure each wire is positioned prop-

connected between these three terminals should indi-

erly and that the wire end is not loose.

cate little or no resistance, or a test light should light.

6. To reconnect connectors properly, push them to-

When the starter switch is OFF, there should be no

gether until they click or snap into place.

continuity between the same terminals.

If the switch or button does not perform properly,

When testing the switches, note the following:

replace it.

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ELECTRICAL SYSTEM

353

124

RIGHT SIDE HANDLEBAR SWITCH

Upper housing without splices

Upper housing with splices

1. Start switch

2. Stop switch

3. Conduit

3. Conduit or splices

4. Phillips screw and

4. Splices

washer

5. Cable strap

5. Bracket

Left handlebar switch description

Handlebar Switch Replacement

The left side handlebar switch housing (Figure

1. Remove the screws securing the left side switch

121) is equipped with the following switches:

housing (Figure 121) to the handlebar. Then care-

1. Headlight HI-LO beam.

fully separate the switch housing to access the de-

2. Horn.

fective switch (Figure 123).

3. Left side turn signal.

2. Remove the screws securing the right side

4. Siren on/off (FXDP models).

switch housing (Figure 122) to the handlebar. Then

5. Clutch lockout (FXDP models).

carefully separate the switch housing to see the de-

fective switch (Figure 124).

Right handlebar switch description

NOTE

To service the front brake light switch,

The right side handlebar switch housing (Figure

refer to Front Brake Light Switch

122) is equipped with the following switches:

Replacement in this chapter.

1. Engine stop/run.

2. Starter.

3A. On models without splices, remove the screw

3. Right side turn signal.

and bracket.

4. Front brake light.

3B. On models with splices, remove the cable strap.

5. Pursuit (FXDP models).

4. Pull the switch(es) out of the housing.

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354

CHAPTER EIGHT

5. Cut the switch wire(s) from the defective

switch(s).

125

6. Slip a piece of heat shrink tubing over each wire

cut in Step 2.

7. Solder the wire end(s) to the new switch. Then

shrink the tubing over the wire(s).

8. Install the switch by reversing these steps, plus

the following:

a. When clamping the switch housing onto the

handlebar, check the wiring harness routing

position to make sure it is not pinched be-

tween the housing and handlebar.

b. To install the right side switch housing, refer

9. To install the right side switch housing, refer to

to Throttle and Idle Cable Replacement in

Throttle and Idle Cable Replacement in Chapter

Chapter Seven.

Seven.

WARNING

Do not ride the motorcycle until the

throttle cables are properly adjusted.

Also, the cables must not catch or

Likewise, the cables must not catch or

pull when the handlebars are turned.

Improper cable routing and adjust-

ment can cause the throttle to stick

open. This could cause loss of con-

open. This could cause loss of control.

trol. Recheck all work before riding

Recheck the work before riding the

the motorcycle.

motorcycle.

Front Brake Light Switch Replacement

Ignition/Light Switch

The front brake light switch (Figure 125) is

Removal/Installation

mounted in the right side switch lower housing.

1. Separate the right side switch housing as de-

FXDWG and FXDP models

scribed under Handlebar Switch Replacement in

1. Disconnect the negative battery cable as de-

this chapter.

scribed in this chapter.

2. If still in place, remove the wedge between the

2. Turn the ignition switch OFF and remove the ig-

switch and the switch housing.

nition key.

3. While depressing the switch plunger, slowly ro-

3A. On FXDWG models (Figure 126), remove the

tate the switch upward, rocking it slightly, and re-

acorn nut from the instrument panel on the fuel

move it from the switch housing.

tank.

4. Cut the switch wires from the defective switch.

3B. On FXDP models (Figure 127), remove the

5. Slip a piece of heat shrink tubing over each wire

four screws and washers from the center console on

cut in Step 4.

the fuel tank.

6. Solder the wire ends to the new switch. Then

4. Lift the instrument panel, or center console, up

shrink the tubing over the wires.

and then turn it over. Place a heavy cloth under the

7. Install the switch by reversing these steps, plus

instrument panel to avoid scratching the fuel tank.

the following.

8. When clamping the switch housing onto the han-

NOTE

dlebar, check the wiring harness routing position to

Before disconnecting the wires in Step

make sure it is not pinched between the housing and

5, confirm the wire color connections

handlebar.

at the ignition switch with the wiring

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356

CHAPTER EIGHT

diagram for the model being worked

on.

128

5. Disconnect the ignition switch wires from the ig-

nition switch.

6. Remove the ignition switch mounting screws.

Then remove the ignition switch.

7. Reverse these steps to install the new ignition

switch.

8. Check the switch in each of its operating posi-

tions.

129

All models

except FXDWG and FXDP

1. Remove the seat as described in Chapter Thir-

teen.

2. Disconnect the negative battery cable as de-

scribed in this chapter.

3. Turn the ignition switch OFF and remove the ig-

nition key.

4. Loosen and remove the outer chrome nut secur-

ing the ignition switch to the mounting plate (Fig-

Oil Pressure Switch

ure 128).

5. Push the ignition switch through the cover (to-

Operation

ward inside) and remove it from the mounting plate

The oil pressure switch is located on the front

(Figure 129).

right side of the crankcase.

6. Remove the ignition switch harness cover and

A pressure-actuated diaphragm-type oil pressure

cut the switch wires 3 in. (76.2 mm) from the

switch is used. When the oil pressure is low or when

switch.

oil is not circulating through a running engine, spring

7. To reconnect the new ignition switch:

tension inside the switch holds the switch contacts

a. Slide the replacement conduit onto the wire

closed. This completes the signal light circuit and

harness.

causes the oil pressure indicator lamp to light.

The oil pressure signal light should turn on when

b. Match the ignition switch and wire harness

any of the following occurs:

color codes, and then install new butt connec-

1. The ignition switch is turned on prior to starting

tors to the wire harness and ignition switch

the engine.

wires. Seal the butt splice connectors as

2. The engine idle is below 1000 rpm.

shown in Figure 130.

3. The engine is operating with low oil pressure.

8. Install the ignition switch into the hole in the

4. Oil is not circulating through the running engine.

switch cover so that the TOP mark stamped on the

switch body faces up (toward the switch position

decal).

Testing/replacement

9. Tighten the ignition switch locknut securely.

NOTE

10. Check the switch operation in each of its oper-

The oil pressure signal light may not

ating positions.

come on when the ignition switch is

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ELECTRICAL SYSTEM

357

turned off and then back on immedi-

130

SEALED BUTT

ately. This is due to the oil pressure

CONNECTOR INSTALLATION

retained in the oil filter housing.

The following steps test the electrical part of the

STEP 1

oil pressure switch. If the oil pressure switch, indi-

Metal insert

cator lamp and related wiring are in good condition,

inspect the lubrication system as described in Chap-

ter Two.

1. Remove the rubber boot and disconnect the elec-

STEP 2

Insert stripped wire

trical connector from the switch (Figure 131).

ends into connector

2. Turn the ignition switch ON.

3. Ground the switch wire to the engine.

4. The oil pressure indicator lamp on the instru-

ment panel must light.

5. If the signal indicator lamp does not light, check

Crimp wire ends

STEP 3

for a defective indicator lamp and inspect all wiring

between the switch and the indicator lamp.

Heat and allow

connector to cool

6A. If the oil pressure warning light operates prop-

erly, attach the electrical connector to the pressure

switch. Make sure the connection is tight and free

from oil. Slide the rubber boot back into position.

Melted sealant

6B. If the warning light remains ON when the en-

gine is running, shut the engine off. Check the en-

gine lubrication system as described in Chapter

Two.

7. To replace the switch, perform the following:

131

a. Unscrew it from the engine.

b. Apply Loctite pipe sealant with Teflon to the

switch threads prior to installation.

c. Install the switch and tighten to the specifica-

tion in Table 6.

d. Test the new switch as described in Steps 1-4.

Neutral Indicator Switch Replacement

The neutral indicator switch is located on the

transmission top cover. The neutral indicator light

on the instrument panel must light when the igni-

132

tion is turned ON and the transmission is in

NEUTRAL.

1. Disconnect the electrical connector from the

neutral indicator switch (Figure 132).

2. Turn the ignition switch on.

3. Ground the neutral indicator switch wire to the

transmission.

4. If the neutral indicator lamp lights, the neutral

switch is defective. Replace the neutral indicator

switch and retest.

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358

CHAPTER EIGHT

5. If the neutral indicator lamp does not light, check

for a defective indicator lamp, faulty wiring or a

133

loose or corroded connection.

NOTE

The electrical connector can be at-

tached to either stud on the switch.

6A. If the neutral switch operates correctly, attach

the electrical connector to the neutral switch. Make

sure the connection is tight and free from oil.

6B. If the neutral switch is defective, replace the

neutral indicator switch.

7. To replace the old switch, perform the following:

a. Shift the transmission into NEUTRAL.

134

b. Unscrew and remove the old switch and

O-ring from the transmission top cover.

c. Apply clean transmission oil to the new

O-ring seal.

d. Install the new switch and tighten to the spec-

ification in Table 6.

Rear Brake Light Switch

Testing/Replacement

A hydraulic, normally-open rear brake light

c. If the switch fails either of these tests, replace

switch is used on all models. The rear brake light is

the switch.

attached to the rear brake caliper brake hose (Fig-

Place a drip pan under the switch, as some

ure 133). When the rear brake pedal is applied, hy-

brake fluid will drain out when the switch is re-

draulic pressure closes the switch contacts,

moved.

providing a ground path so the rear brake lamp co-

mes on. If the rear brake lamp does not come on,

6. Loosen and remove the switch from the fitting

perform the following.

on the rear brake line.

7. Thread the new switch into the fitting and

NOTE

tighten securely.

Removal of the exhaust system is not

8. Reconnect the switch electrical connectors.

necessary, but it does provide addi-

9. Bleed the rear brake as described in Chapter

tional work room for this test and re-

placement if necessary.

Twelve.

10. Check the rear brake light with the ignition

1. If necessary, remove the exhaust system as de-

switch turned ON and the rear brake applied.

scribed in Chapter Seven.

2. Turn the ignition switch OFF.

HORN

3. Disconnect the electrical connector from the

switch (Figure 134).

The horn is mounted on the frame boss on the left

4. Connect an ohmmeter between the switch termi-

side of the frame.

nals and check the following:

a. Apply the rear brake pedal. There must be

continuity.

Testing

b. Release the rear brake pedal. There must be

no continuity.

1. Remove the seat.

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ELECTRICAL SYSTEM

359

a. Make sure the electrical connectors and horn

135

spade terminals are free of corrosion.

b. Connect the black wire connector to the top

(silver) horn terminal.

c. Connect the yellow/black wire connector to

the bottom (gold) horn terminal.

d. Check that the horn operates correctly.

ELECTRIC PANEL

The electric panel assembly mounts on the left

side of the motorcycle. The panel assembly houses

the circuit breaker, fuses, ignition module, starter

2. Disconnect the negative battery cable as de-

relay, turn signal canceller, security module (mod-

scribed in this chapter.

els so equipped) and the main wiring harness con-

3. Disconnect the electrical connectors from the

nector.

backside of the horn.

Refer to Figure 136 (1999-2000 models) and

4. Connect a 12-volt battery to the horn as fol-

Figure 137 (2001-on models).

lows:

1. Disconnect the negative battery cable as de-

a. Connect the negative lead to the top (silver)

scribed in this chapter.

horn terminal.

2. Carefully pull out and remove the electric panel

b. Connect the positive lead to the bottom (gold)

cover (Figure 138).

horn terminal.

3. Remove the nuts securing the outer panel (Fig-

5. If the horn is good, it will sound. If not, replace

ure 139) and remove the outer panel.

the horn.

4. Install the outer panel (Figure 139) and tighten

6. Reconnect the electrical connectors to the horn

the nuts.

as follows:

5. Correctly position the electrical panel cover with

the this side down label facing down (Figure 140).

a. Connect the black wire connector to the top

6. Carefully push the electric panel cover (Figure

(silver) horn terminal.

138) back into position. Push it on until it bottoms.

b. Connect the yellow/black wire connector to

the bottom (gold) horn terminal.

7. Connect the negative battery cable as described

TURN SIGNAL MODULE

in this chapter.

(1999-2000 MODELS)

The turn signal module (TSM) is an electronic

Replacement

microprocessor that controls the turn signals and the

four-way hazard flasher. The turn signal module re-

1. Remove the seat as described in Chapter Thir-

ceives its information from the speedometer and

teen.

turn signal switches.

2. Disconnect the negative battery cable as de-

The turn signal module is located in the electrical

scribed in this chapter.

panel on the left side of the frame.

3. Remove the long acorn nut (A, Figure 135) se-

If the following tests do not solve or confirm the

curing the horn assembly bracket to the frame post.

problem with the TSM, have a Harley-Davidson deal-

4. Move the horn assembly (B, Figure 135) to the

ership test the unit by using the Speedometer Tester

frame and engine and disconnect the electrical con-

along with the specific diagnostic code retrieval.

nectors from the horn terminals.

5. Remove the screw and nut securing the horn to

Operation

the mounting bracket and remove the horn.

6. Install the horn by reversing these removal steps.

For example, when the rider signals for left turn,

Note the following:

the following occurs. Refer to Figure 141.

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 18