HOME

CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8.30

GENERAL f1368a8x

The Cruise Control system provides automatic vehicle speed

control. The electronics and stepper motor are contained in a
control module mounted under the left side cover. The step-
per motor actuates the cruise control cable through a gear
train and ribbon reel.

SYSTEM OPERATION
Set/Resume
To engage and disengage the cruise control system, proceed Switch
as follows:
1. While riding in fourth or fifth gear, turn the Cruise ON/
OFF Switch to the ON position. See Figure 8-123. The
switch is located on the fairing cap of FLHTCU models,
the instrument nacelle of FLTR models, and the left han-
dlebar lower switch housing on FLHRC models. The
Cruise Enabled/Engaged lamp in the tachometer face Figure 8-124. Right Handlebar Switch Assembly
(speedometer on FLHRC models) turns red to indicate (FLTR, FLHTCU)
that the system is activated. See Figure 8-125. A red
lamp in the switch on both FLHTCU and FLTR models
f2160x8x Tachometer
also indicates this condition to the rider.
2. Power (12 vdc) is supplied to the cruise control module
through a 15 amp fuse located in the fuse block mounted
under the left side cover.
3. With the motorcycle traveling at the desired “cruise” 50 60 70 40
30 50
speed (30 mph/48 km/h to 85 mph/137 km/h), momen- 40 80
tarily push the Cruise SET/RESUME switch to SET. See 30 90 20 60
MPH RPM x100
Figure 8-124. 20 100
10 70
10 110
0 120 0 80
Ignition/Light
Key Switch C
H A E R TIFI E D HA
R L E Y-D A VI D S O N
R L E Y-D A VI D S O N
Cruise ON/OFF
Switch

Cruise Enabled/Engaged Lamp

Figure 8-125. Instrument Panel (FLHTCU)

The cruise control module “reads” the vehicle speed

sensor (VSS) output to establish the desired vehicle
speed. The module then sends a signal to the stepper
motor which drives the ribbon reel to take up the slack in
the cruise cable. The Cruise Enabled/Engaged lamp in
the tachometer face (speedometer on FLHRC models)
turns from red to green to indicate that the cruising
speed is locked in. See Figure 8-125.
f2031x8x 4. The cruise control module monitors both the engine
RPM and the VSS output speed signal. The module sig-
Figure 8-123. Fairing Cap (FLHTCU) nals the stepper motor to open or close the throttle to
keep the speedometer output speed signal constant.
The engine RPM is monitored to detect engine

2004 Touring: Electrical 8-99

HOME

ENGAGE SEQUENCE DISENGAGE SEQUENCE

CRUISE SWITCH ON

FRONT/REAR BRAKE
SET/RESUME
SWITCH TO SET

IDLE CABLE ROLL-OFF

READS VSS (DISENGAGE) SWITCH
OUTPUT SPEED SIGNAL

CRUISE
CRUISE SWITCH OFF
STEPPER MOTOR MODULE
GEAR TRAIN
& RIBBON REEL
CRUISE ENGAGED
HANDLEBAR
LAMP
ENGINE STOP
SWITCH OFF
THROTTLE
ACTUATION ENGINE RPM
MONITORED*
CLUTCH DISENGAGE
(ENGINE RPM)
*Tachometer receives signal from ignition coil on
carbureted models, and from ECM on EFI models.

Figure 8-126. Cruise System Diagram

overspeed, a condition which automatically causes f. Handlebar mounted Cruise SET/RESUME switch is
cruise disengagement. pushed to SET and held in that position until vehicle
speed drops below 30 mph (48 km/h).
5. The cruise control automatically disengages (stepper
motor drives cruise cable to the full-out position) when- NOTE
ever the cruise control module receives one of the fol- If the vehicle speed is above 30 mph (48 km/h) when the
lowing inputs: Cruise SET/RESUME Switch is released, then the cruise
system automatically re-engages.
a. Front or rear brake is applied.
b. Throttle is “rolled back” or closed, thereby actuating
idle cable roll-off (disengage) switch.
CABLE ADJUSTMENT
c. Motorcycle clutch is disengaged (module senses
too great an increase in RPM).
NOTE
d. Cruise ON/OFF Switch placed in the OFF position. Always adjust the cables in the sequence presented below,
The switch is located on the fairing cap of FLHTCU that is, throttle and then idle cable. The cruise cable only
models, the instrument nacelle of FLTR models, and requires adjustment if the cruise module or cruise cable are
the left handlebar lower switch housing on FLHRC removed or replaced, and then it must be adjusted last using
models. The green Cruise Enabled/Engaged lamp the CABLE LASH INITIALIZATION routine on the next page.
in the tachometer face (speedometer on FLHRC
models) is extinguished to indicate that the system
is deactivated. The red lamp in the fairing cap switch THROTTLE CABLE
of FLHTCU models and the instrument nacelle
switch of FLTR models is also extinguished. 1. With handlebar in straight ahead position, idle cable
adjusted to full slack and throttle control grip turned to
e. Handlebar mounted Engine Stop Switch placed in wide open throttle (WOT), adjust pull open cable to
the OFF position. (This removes tachometer input obtain full throttle opening at carburetor/induction mod-
signal which results in module disengagement.) ule.

8-100 2004 Touring: Electrical

HOME

2. Twist throttle grip to full closed position. Check that idle CABLE LASH INITIALIZATION
stop-screw is touching idle stop with handlebar in
straight ahead position, and while turning handlebar With the elimination of the mechanical cruise cable adjuster,
from “lock-to-lock”. the tolerance stack-ups are intended to result in a cable that
is too long. The extra cable length is then taken up upon exe-
NOTE cution of the Cable Lash Initialization routine. During the rou-
If idle stop-screw is not touching idle stop, adjust (loosen) tine, the system calculates the number of “motor steps” the
pull-open cable just enough so that contact is made through cable is pulled before the throttle plates are moved (a maxi-
full lock-to-lock handlebar movement. Also check that cruise mum of 200 motor steps equivalent to 1.2 inches or 31 mm).
cable has slack and is not opening throttle. Loosen cruise This information is then stored in permanent memory.
cable if required.
NOTE
3. Rotate throttle grip to WOT and release. Throttle must Perform the initialization routine whenever the cruise module,
return to idle position freely. If it does not, check for cruise cable or throttle body are removed or replaced. For
incorrect cable routing, damaged cables or binding in the best results, be sure the engine is at normal operating tem-
throttle grip. perature and throttle and idle cables are correctly adjusted
and operational.
To set the correct cable lash, proceed as follows:
IDLE CABLE
a. Push the Cruise Switch on the right handlebar to
1. Remove left side saddlebag. See Section 2.25 SAD- RESUME and hold.
DLEBAG, REMOVAL.
b. Turn the Cruise ON/OFF switch to ON.
2. Gently pull side cover from frame downtubes (no tools
c. Turn the Ignition/Light Key Switch to IGNITION.
required).
d. Start the engine. The green Cruise Enabled/
3. Lift the locking latch and remove the cruise module con- Engaged lamp in the tachometer face (speedometer
nector [17]. With idle cable still adjusted to full slack posi- on FLHRC models) will illuminate. Wait 3 seconds
tion, connect ohmmeter to violet/yellow and orange/ for the lamp to go off.
violet leads on connector [17A].
e. Release the Cruise Switch from the RESUME posi-
4. Ohmmeter must indicate infinity (switch contacts open). tion.
If ohmmeter indicates continuity, the roll-off switch may
f. Push the Cruise Switch to RESUME and hold.
be shorted and entire cable must be replaced.
Cruise will pull in cable until change in RPM is
5. With handlebar in straight ahead position, adjust idle detected. The number of motor steps required to rev
cable until approximately 0.06 inch (1.5 mm) of freeplay the engine is stored in memory.
exists at the outside diameter (OD) of the throttle grip. g. After engine revs and Cruise Enabled/Engaged
6. With light force, rotate the throttle grip toward the closed lamp is extinguished, release the Cruise Switch
position. The ohmmeter must indicate continuity. If it from the RESUME position.
does not, decrease freeplay at throttle grip by adjusting h. Turn the Ignition/Light Key Switch to OFF.
the idle cable to obtain continuity while maintaining
some freeplay at the throttle grip.
7. While holding the throttle grip (with light force) in the THROTTLE/IDLE CABLES
closed position, turn handlebar from “lock-to-lock”. Ohm-
meter must indicate continuity throughout handlebar
movement. NOTE
While the same throttle cable is used on all Touring models,
8. With handlebar in straight ahead position, rotate throttle the idle cable of “cruise” models is provided with a cruise roll-
grip to WOT and release. Throttle must return to idle off (disengage) switch.
position freely.
9. Repeat step 8 with handlebar at full left and right posi- REMOVAL
tions. If throttle does not return to idle position freely, 1. See Section 2.21 THROTTLE CABLES (NON-CRUISE),
loosen idle cable slightly and repeat steps 6-9. REMOVAL, THROTTLE SIDE.
10. Install cruise module connector [17] and engage locking 2. Remove the air cleaner and backplate. See Section 4.5
latch. AIR CLEANER, REMOVAL.
11. Align barbed studs in side cover with grommets in frame 3. Raise fuel tank to access cables in area of frame back-
downtubes and push firmly into place (no tools bone. For carbureted models, see Section 4.7 FUEL
required). TANK (CARBURETED), PARTIAL REMOVAL, FLHT/C,
12. Install left side saddlebag. See Section 2.25 SADDLE- or FLHR/S. For fuel injected models, see Section 9.4
BAG, INSTALLATION. FUEL TANK (FUEL INJECTED), PARTIAL REMOVAL,
FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

2004 Touring: Electrical 8-101

HOME

Main
Harness

Female Spade
Terminal
Insulator
Cruise Control
Roll-Off Switch
External (Under Boot)
Step
Switch Spade
Contact Idle Cable

f2037x8x
Throttle Cable

Figure 8-127. Throttle/Idle Cable Configuration (Right Side View)

4. Locate the cruise control roll-off switch plumbed into the 2. Route the throttle and idle cables as follows:
idle cable on the right side of the vehicle. See Figure 8-
127. Push rubber boot on switch forward to access FLHTCU: Route the cables downward following the
spade type wire terminals. brake line to the inner fairing. Pass the cables through
the inner fairing grommet and then loop them toward the
5. Remove both female spade type terminals from spade rear along the right side of the steering head.
contacts on cruise control roll-off switch.
FLHRC: Route the cables downward following the right
6. Carbureted: Using a needle nose pliers, carefully pull handlebar to the handlebar clamp shroud. Pass the
idle cable barrel from upper inboard hole in throttle cables through the opening in the shroud and then loop
wheel. Pull throttle cable barrel from remaining hole. them toward the rear along the right side of the steering
Release idle and throttle cables from guides in throttle head. Capture cables in J-clamp and then start screw
cable bracket. (with flat washer) to fasten J-clamp to wellnut in right
Induction Module: Using a needle nose pliers, carefully side of steering head. Tighten screw to 9-18 in-lbs (1.0-
pull idle cable barrel from upper hole in throttle wheel. 2.0 Nm).
Pull throttle cable barrel from lower hole. Using slots,
3. Route the throttle and idle cables rearward along the
release idle and throttle cables from guides in throttle
right side of the frame backbone. After passing through
cable bracket.
J-clamp riveted to frame backbone, route cables down-
7. Free cables from J-clamp riveted to right side of frame ward to carburetor/induction module.
backbone.
4. Use a pliers to straighten spade contacts of cruise roll-
8. If present, remove screw (with flat washer) to release J- off switch if bowed or bent back. The contacts must be
clamp from wellnut in right side of steering head. parallel and line up perpendicular to the idle cable.
Remove J-clamp from cables.
5. Separate the cruise roll-off switch wires up to the point
where they enter the wire harness conduit. Now route
INSTALLATION the leads straight down.

1. See Section 2.21 THROTTLE CABLES (NON-CRUISE), 6. Orient the idle cable so that the spade contacts are at
INSTALLATION, THROTTLE SIDE. the top.

8-102 2004 Touring: Electrical

HOME

7. Slide the insulators onto the switch spade contacts cables as necessary to keep barrel ends from dislodg-
(polarity is not a factor). For maximum insertion, be sure ing. Verify operation by turning throttle grip and observ-
that the external step on the insulators face each other. ing cable action.
See Figure 8-127.
12. Install fuel tank. For carbureted models, see Section 4.7
8. Fit the rubber boot over the cruise control roll-off switch. FUEL TANK (CARBURETED), INSTALLATION (AFTER
An oval cut in the boot accommodates the switch spade PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel
terminal connections. injected models, see Section 9.4 FUEL TANK (FUEL
9. Position the throttle cable below the idle cable. INJECTED), INSTALLATION (AFTER PARTIAL
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
10. Carbureted: Install sleeve on throttle cable housing into
shorter cable guide in throttle cable bracket. Drawing 13. Install backplate and air cleaner assembly. See Section
throttle cable downward, fit barrel end into lower out- 4.5 AIR CLEANER, INSTALLATION.
board hole in throttle wheel. Install sleeve and spring on
14. Adjust the throttle and idle cables. Be sure to use the
idle cable housing into longer cable guide inserting bar-
cable adjustment procedure for Ultra models. See
rel end into upper inboard hole in throttle wheel.
CABLE ADJUSTMENT, in this section.
Induction Module: Install sleeve on throttle cable hous-
ing into shorter cable guide at top of throttle cable
bracket. Drawing throttle cable downward, fit barrel end CRUISE CABLE
into lower hole in throttle wheel. Install sleeve and spring
on idle cable housing into longer cable guide at bottom
of throttle cable bracket inserting barrel end into upper
hole in throttle wheel.
REMOVAL
11. Verify that cables are fully seated in channel of throttle 1. Remove the air cleaner and backplate. See Section 4.5
wheel, and using cable adjusters at handlebar, tighten AIR CLEANER, REMOVAL.

f2206x8x Cruise Cable Cruise Module

Connector

Cruise Module
Connector [17]

Spare Fuse
Holder
Maxi-Fuse
Fuse Block
Holder

Figure 8-128. Cruise Control Module (Under Left Side Cover)

2004 Touring: Electrical 8-103

HOME

7. Pull the cable out of the connector and remove the cable
f1965x8x
end bead from the ribbon end eyelet. See Figure 8-130.
8. Pull anchored cable clip from hole in frame crossmem-
ber. See Figure 8-131.
9. Carefully pull cruise cable from beneath fuel tank draw-
ing it out through hole in frame crossmember.

INSTALLATION
Wheel Pin 1. Draw the cruise cable forward along the left side of the
frame backbone, and then route the cable toward the
right side of the vehicle in front of the top engine stabi-
End Fitting lizer bracket.
2. Slide groove in cruise cable end fitting over cap of wheel
pin. Push on end fitting until it snaps in place. See Figure
8-129.
Figure 8-129. Remove End Fitting From Wheel Pin
3. Using slot, slip cruise cable housing into cable guide in
throttle cable bracket. At bottom of bracket, install new
2. Remove E-clip from sleeve at end of cruise cable hous- E-clip on sleeve at end of cruise cable housing.
ing. Discard E-clip. Using slot, remove cruise cable
housing from cable guide in throttle cable bracket. 4. Feed cruise cable and connector through hole in frame
crossmember. See Figure 8-131.
3. Push the plastic end fitting on the cruise cable to the out-
board side to release from wheel pin. See Figure 8-129.
CAUTION
4. Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL. Be sure that the ribbon is not twisted. A twisted ribbon
5. Gently pull side cover from frame downtubes (no tools may adversely affect performance or even prevent cruise
required). operation.

6. Rotate cruise cable connector in a counterclockwise 5. With the hole in the ribbon end eyelet and the flat on the
direction to detach from cruise module. See Figure 8- cable connector housing facing outboard, fit cable end
128. bead into ribbon end eyelet. See Figure 8-130.

Flat Ribbon

Cruise
Module

Ribbon End
Eyelet
Cruise Cable
Connector Cable End
Bead

f1549x8x

Figure 8-130. Remove Cable End Bead From Ribbon End Eyelet

8-104 2004 Touring: Electrical

HOME

1WARNING
f1548x8x

Cruise
Cable Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.

4. Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.
Cable Clip
5. Unthread bolt and remove battery positive cable (red)
from battery positive (+) terminal.
Hole
6. Using a T40 TORX drive head, loosen bolt to move lip of
hold-down clamp off edge of battery. Remove battery
from battery box.
7. Lift the locking latch and remove the cruise module con-
nector [17]. See Figure 8-128.
Figure 8-131. Cruise Cable Routing (Left Side)
8. Rotate cruise cable connector in a counterclockwise
direction to detach from cruise module.
6. Verify that bead, eyelet and ribbon are lined up correctly. 9. From inside battery box, remove three flange bolts.
If necessary, remove plastic end fitting from wheel pin Carefully pull cruise module away from side of battery
and gently pull on end fitting to remove cable slack. box exercising caution to avoid losing grommets.
Reinstall end fitting, if removed.
7. Insert cruise cable connector into cruise module and
rotate in a clockwise direction until tabs on connector INSTALLATION
fully engage grooves or detentes in cruise module hous-
ing. 1. Install grommets into holes on left side of battery box
8. Capture cruise cable in cable clip and anchor in hole of with the larger OD on the outboard side. See Figure 8-
frame crossmember. See Figure 8-131. 132.

9. Adjust the throttle and idle cables. See CABLE ADJUST- 2. Align threaded holes on inboard side of cruise module
MENT, in this section. with holes in grommets and install flange bolts from
inside battery box.
10. Install backplate and air cleaner assembly. See Section
4.5 AIR CLEANER, INSTALLATION. 3. Alternately tighten flange bolts to 60-96 in-lbs (6.8-10.9
Nm). Install cruise module connector [17] and engage
11. Align barbed studs in side cover with grommets in frame locking latch.
downtubes and push firmly into place (no tools
required).
12. Install left side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION. f2004x8x
Mounting
13. Perform the CABLE LASH INITIALIZATION routine des- Holes
cribed in this section.

CRUISE CONTROL MODULE

REMOVAL
1. Remove the air cleaner and backplate. See Section 4.5
AIR CLEANER, REMOVAL.
2. Push the plastic end fitting on the cruise cable to the out-
board side to release from wheel pin. See Figure 8-129.
3. Remove seat. See Section 2.24 SEAT, REMOVAL. Figure 8-132. Battery Box (Right Side View)

2004 Touring: Electrical 8-105

HOME

CRUISE CONTROL SWITCHES

CAUTION

Be sure that the ribbon is not twisted. A twisted ribbon

may adversely affect performance or even prevent cruise FAIRING CAP
operation.
See Figure 8-133. For instructions on replacement of the
CRUISE ON/OFF SWITCH, see Section 8.19 FAIRING
4. With the hole in the ribbon end eyelet and the flat on the
CAP SWITCHES (FLHTC/U), Section 8.20 INSTRU-
cable connector housing facing outboard, fit cable end
MENT NACELLE SWITCHES (FLTR), or Section 8.21
bead into ribbon end eyelet. See Figure 8-130.
HANDLEBAR SWITCHES (FLHRC).
5. Verify that bead, eyelet and ribbon are lined up correctly.
If necessary, remove plastic end fitting from wheel pin
and gently pull on end fitting to remove cable slack. Cruise ON/OFF
Switch
6. Insert cruise cable connector into cruise module and
rotate in a clockwise direction until tabs on connector
fully engage grooves or detentes in cruise module hous-
ing.

7. Install the cruise module connector [17] until locking

latch engages. See Figure 8-128.

8. Place battery in battery box, terminal side forward.

Rotate hold-down clamp so that lip (with rubber pad)
rests on edge of battery and tighten clamp bolt.

1WARNING
f2031x8x
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
Figure 8-133. Fairing Cap (FLHTCU)
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.

9. Insert bolt through battery positive cable (red) into HANDLEBAR

threaded hole of battery positive (+) terminal. Tighten
See Figure 8-134. For instructions on replacement of the
bolt to 60-96 in-lbs (6.8-10.9 Nm).
handlebar mounted CRUISE SET/RESUME switch, see
10. Insert bolt through battery negative cable (black) into Section 8.21 HANDLEBAR SWITCHES, SWITCH
threaded hole of battery negative (-) terminal. Tighten REPAIR/REPLACEMENT.
bolt to 60-96 in-lbs (6.8-10.9 Nm).
f1368a8x
11. Install seat. See Section 2.24 SEAT, INSTALLATION.

12. Slide groove in cruise cable end fitting over cap of wheel
pin. Push on end fitting until it snaps in place. See Figure
8-129.

13. Install backplate and air cleaner assembly. See Section

4.5 AIR CLEANER, INSTALLATION.

14. Perform the CABLE LASH INITIALIZATION routine des-

cribed in this section.
Set/Resume
Switch

AUDIO HARNESS

For instructions on replacement of the audio harness,

see Section 8.32 WIRING HARNESSES AND CABLES,
AUDIO HARNESS (FLHTCU). Figure 8-134. Right Handlebar Switch Assembly
(FLTR, FLHTCU)

8-106 2004 Touring: Electrical

HOME

PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8.31

RADIO (FLHTC/U)
Radio [28] f2238x8x
CB Antenna Gray
Cable [50]
REMOVAL Ultra Only
Ultra Only

1. Remove seat. See Section 2.24 SEAT, REMOVAL. Radio Antenna

Radio [27] Cable [51]
Black
1WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.

CAUTION

To prevent possible damage to the sound system,

always verify that the Ignition/Light Key Switch is in the
OFF position before disconnecting the battery negative
cable from the battery terminal.
2. Verify that the Ignition/Light Key Switch is in the OFF 1 2 3
position. Unthread bolt and remove battery negative
cable (black) from battery negative (-) terminal.
3. Remove the outer fairing. See Section 2.29 UPPER 1. Main to Interconnect [1]
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/ 2. Main to Interconnect [15]
WINDSHIELD, REMOVAL. 3. Ignition/Light Key Switch [33]

NOTE Figure 8-136. Radio Connections - FLHTCU

To separate pin and socket halves of Radio connectors [27]
and [28], use thumbnail to pull down external latch before
b. Radio antenna cable connector [51].
pulling socket from pin side. See Figure 8-135.
c. Radio connector [28], 23-place Amp (gray). Ultra
4. See Figure 8-136. Separate pin and socket halves of the models only.
following connectors: d. CB antenna cable connector [50]. Rotate knurled
a. Radio connector [27], 23-place Amp (black). nut counterclockwise until free. Ultra models only.

f1555x8x f1559x8x

Figure 8-135. Pull Down Latch to Free Radio Connector Figure 8-137. Release Carrier from Fairing Brackets

2004 Touring: Electrical 8-107

HOME

5. Move the following connectors from their fixed locations: 6. Install outer fairing. See Section 2.29 UPPER FAIRING/
WINDSHIELD (FLHT/C/U), OUTER FAIRING/WIND-
a. Main to interconnect harness connector [1], 12- SHIELD, INSTALLATION.
place Deutsch (black); T-stud at front of right fairing
bracket.
CAUTION
b. Main to interconnect harness connector [15], 4-
place Packard (black); anchor in hole at bottom of To prevent possible damage to the sound system,
radio (right side). always verify that the Ignition/Light Key Switch is in the
c. Ignition/light key switch connector [33], 4-place OFF position before connecting the battery negative
Packard; anchor in hole at bottom of radio (center). cable to the battery terminal.

7. Verify that the Ignition/Light Key Switch is in the OFF

6. Using a long shank ball end socket (Snap-on® FABL6E), position. Insert bolt through battery negative cable
remove four screws to release radio from left and right (black) into threaded hole of battery negative (-) termi-
radio support brackets. Use oblong holes in fairing nal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).
brackets to access screws. See Figure 8-137.
8. Install seat. See Section 2.24 SEAT, INSTALLATION.
7. Pull radio forward to remove. If radio nose seal gets
caught on radio support brackets, rock up and down until
free.
FRONT FAIRING SPEAKERS
INSTALLATION
1. Position radio between radio support brackets and push REMOVAL
into approximate position. If radio nose seal gets caught
on radio support brackets, rock up and down while push- 1. Remove the outer fairing. See Section 2.29 UPPER
ing. If necessary, spray nose seal with contact cleaner FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
and repeat step. WINDSHIELD, REMOVAL.

2. Before pushing radio into cut of inner fairing, verify that 2. Carefully pull the socket terminals from the speaker
nose seal is not distorted, compressed or pinched. spade contacts.

3. Align threaded inserts in radio sides with oblong holes in 3. Using a T25 TORX drive head, remove three screws to
left and right radio support brackets. Starting with the release the speaker adapter assembly from the inner
rear screws, install four socket screws to fasten radio to fairing.
brackets. Tighten screws to 35-45 in-lbs (4.0-5.1 Nm).
4. Carefully pull speaker from adapter.
4. See Figure 8-136. Mate pin and socket halves of the fol-
lowing connectors:
a. Radio connector [27], 23-place Amp (black).
INSTALLATION
b. Radio antenna cable connector [51]. 1. With the speaker spade contacts at the top of the
adapter, the top being the side with the widest edge,
c. Radio connector [28], 23-place Amp (gray). Ultra snap speaker into adapter using finger pressure.
models only.
2. If speaker grille is loose, apply 3M-847 adhesive (HD
d. CB antenna cable connector [50]. Insert pin and Part No. 99618-60) to outer edge of adapter ring. Install
rotate knurled nut clockwise until tight. Ultra models grille on adhesive.
only.
3. With the widest edge of adapter at the top, align holes in
5. Return the following connectors to their fixed locations: speaker adapter assembly with those in inner fairing.
a. Main to interconnect harness connector [1], 12-
4. Install two long screws to secure top of speaker adapter
place Deutsch (black); T-stud at front of right fairing
assembly to inner fairing. Capturing fairing support
bracket.
brace, install short screw in lower outboard hole (posi-
b. Main to interconnect harness connector [15], 4- tioning flat washer between adapter and support brace).
place Packard (black); anchor in hole at bottom of The screw hole on the lower inboard side is not used.
radio (right side).
5. Using a T25 TORX drive head, tighten the lower speaker
c. Ignition/light key switch connector [33], 4-place screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten the two
Packard; anchor in hole at bottom of radio (center). upper speaker screws to 35-50 in-lbs (4.0-5.7 Nm).

8-108 2004 Touring: Electrical

HOME
5. Carefully cut anchored cable strap securing main har-
Fuel f2019x8x ness, audio harness, console pod conduit, fuel level
Door sender/fuel pump conduit, and fuel vapor vent tube to
left side of frame backbone. Cut cable strap securing
console pod conduit and audio harness to left frame
tube at front of saddlebag rail.
Pod 6. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws secure
console to clip nuts on the canopy bracket.
7. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment.
Headset
8. Lay a clean shop towel on forward part of the rear
Receptacle
Cap fender. Remove filler cap from neck of fuel tank. Remove
console and lay upside down on shop towel. Reinstall
filler cap.
Console 9. Bend back flexible clamp to release pod cable conduit
from bottom of console.
Figure 8-138. Console Pod Assembly 10. Release Console Pod Connector [53], 12-place Mini-
Deutsch, from attachment clip anchored in hole of frame
crossmember (at rear of battery box). See Figure 8-139.
Depress external latches and use a rocking motion to
6. Install the socket terminals onto the speaker spade con-
separate pin and socket halves.
tacts. Different size spade contacts prevent improper
assembly. 11. Remove three Phillips screws to release pod from con-
sole.
7. Install the outer fairing. See Section 2.29 UPPER FAIR-
ING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
WINDSHIELD, INSTALLATION. INSTALLATION
1. Feed pin housing and conduit through top of console
seating pod in recess. Install three Phillips screws
screws to secure pod to console. Alternately tighten
CONSOLE POD ASSEMBLY screws to 6-11 in-lbs (0.7-1.2 Nm). Capture conduit in
flexible clamp at bottom of console.

NOTE
The following instructions may also be used for replacement Console Pod
Console Pod Cable Conduit
of the chrome fuel tank console on which the pod is mounted. Connector [53]
12-Place Mini-Deutsch
REMOVAL
1. Remove seat. See Section 2.24 SEAT, REMOVAL.

1WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.

2. Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

3. Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

4. Gently pull side cover from frame downtubes (no tools

f2192x8x
required).
Figure 8-139. Disconnect Console Pod Connector

2004 Touring: Electrical 8-109

HOME
6. Mate pin and socket halves of Console Pod Connector
f2007x9x [53], 12-place Mini-Deutsch. Install connector onto
attachment clip anchored in hole of frame crossmember
Console
Pod (at rear of battery box).
Fuel
Tank 7. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
8. Install seat. See Section 2.24 SEAT, INSTALLATION.
Fuel Pump,
9. Align barbed studs in side cover with grommets in frame
Fuel Level
Sender Conduit downtubes and push firmly into place (no tools
required).
10. Install left side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
Fuel
Main
Fuel Vapor Overflow
Harness FRONT HEADSET RECEPTACLE
Vent Tube Hose
Bundle
(To Vapor Valve)

REMOVAL
1. Remove console pod. See CONSOLE POD ASSEM-
Main BLY, REMOVAL, in this section.
Anchored
Console Cable Strap Harness 2. Remove terminals 6 through 12 from pin housing of 12-
Pod Conduit Bundle place Mini-Deutsch connector.
NOTE
For instructions on properly removing wire terminals, see
Figure 8-140. Console Pod Cable/Hose Routing
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
(Top View)
REMOVING/INSTALLING PINS.
3. Raise headset receptacle cap. Place pin punch in either
1WARNING notch of lock ring and rotate in a counterclockwise direc-
tion until loose. See Figure 8-141.
Exercise caution to avoid pinching or kinking the fuel
4. Remove lock ring and cap from headset receptacle.
overflow hose when console is installed. A blocked hose
can cause excess gasoline to remain above the filler 5. Remove headset receptacle from pod.
neck insert, while fuel expansion can cause an overfilled
tank to overflow through the filler cap vent. Gasoline is INSTALLATION
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious 1. From inside pod, insert threaded end of headset recep-
injury. tacle through side hole.

2. Remove filler cap. Place console over filler neck onto

canopy. Route cables from beneath console as shown in
Figure 8-140. Be sure that hoses and wires are not
pinched by the console during installation. Reinstall filler
cap.
Lock Ring
3. Install Allen head screw to fasten rear flange of console
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
4. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
5. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
ness, audio harness, console pod conduit, fuel level
sender/fuel pump conduit, and fuel vapor vent tube. See
f2020x8x
Figure 8-140. Install new cable strap to secure console
pod conduit and audio harness to left frame tube at front
Figure 8-141. Remove Lock Ring from Receptacle
of saddlebag rail. Cut any excess cable strap material.
Using Pin Punch

8-110 2004 Touring: Electrical

HOME

2. Place receptacle cap over end of headset receptacle so

that it seats in recess of pod.
Speaker
3. Open cap, and with the notches on the outboard side, Box
thread lock ring onto headset receptacle.
Switch
4. Place pin punch in either notch of lock ring and rotate in
Bracket
a clockwise direction until tight.
5. Install terminals 6 through 12 into pin housing of 12-
place Mini-Deutsch connector.
TORX
Table 8-16. Front Headset Receptacle Screw

Chamber
Wire Color
Number
Blue/Yellow 6
Yellow/Black 7
Yellow/White 8 f1492b8x

Yellow/Red 9
Figure 8-142. Remove Passenger Switch Assembly
Black 10 (Right Side Speaker Box Shown)
Red 11
Black (Thick Insulation) 12
4. Remove speaker from speaker box and carefully pull
socket terminals from speaker spade contacts.
NOTE
5. Remove trim ring and gently pull on wire harness to
For instructions on properly installing wire terminals, see draw 6-place Mini-Deutsch connector out of speaker
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS, box.
REMOVING/INSTALLING PINS.
6. Depress external latch on socket housing side and use a
rocking motion to separate pin and socket halves of
6. Install console pod. See CONSOLE POD ASSEMBLY,
Mini-Deutsch connector.
INSTALLATION, in this section.
7. Draw socket half of Mini-Deutsch connector back into
7. Test operation of headset receptacle.
speaker box and pull out through speaker hole.
8. Using a T25 TORX drive head, remove two screws to
release switch bracket from inside of speaker box.
REAR HEADSET RECEPTACLE Remove bracket using slot to free switch wires. See Fig-
ure 8-142.
See Section 8.32 WIRING HARNESSES AND CABLES, 9. Pull switch housing assembly, wire harness conduit,
AUDIO HARNESS (FLHTCU). speaker terminals and Mini-Deutsch socket from
speaker box using switch housing hole on outboard side.
10. Carefully pull keycap from switch shaft. Remove switch
REAR PASSENGER SWITCHES from switch housing.
11. Remove terminals 1 through 4 from socket housing.
NOTE
REMOVAL
For instructions on properly removing wire terminals, see
NOTE APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
Right and left side replacement passenger switch assem- REMOVING/INSTALLING SOCKETS.
blies are interchangeable. 12. Pulling one wire at a time, remove four wires from con-
duit.
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Open Tour-Pak. INSTALLATION
3. Using a T10 TORX drive head, remove four screws and 1. Pushing one wire at a time, feed four wires of new switch
pull speaker grille from speaker box. through conduit.

2004 Touring: Electrical 8-111

HOME

f1494b8x

Passenger
Switch

Slot faces toward the front

on right side switch assembly,
toward the rear on left side.
Slot

Cavity

Switch f1491x8x
Housing DISASSEMBLED

Figure 8-144. Properly Orient Switch Bracket

Speaker
Box

Switch
Bracket
Pink/White
Keycap Wire
Rib
Slot
Forward

ASSEMBLED
f1495x8x

Figure 8-143. Install Switch in Housing Rib

Bottom

2. Install terminals 1 through 4 into socket housing.

Table 8-17. Rear Passenger Switches

Chamber
Wire Color
Number

Pink/White 1
Gray/White 2
Violet/Black 3 f1492x8x

* Orange/Black 4
Figure 8-145. Install Passenger Switch Assembly
* Mates to O/BK on [41A], BN/W on [42A]. (Right Side Speaker Box Shown)

8-112 2004 Touring: Electrical

HOME

NOTE REAR SPEAKERS

For instructions on properly installing wire terminals, see
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING SOCKETS. REMOVAL
3. With the Pink/White wire at the bottom, place switch in 1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
cavity of switch housing. Bottom of the assembly is MAXI-FUSE, REMOVAL.
determined by location of rib on switch housing. See Fig-
2. Open Tour-Pak.
ure 8-143.
3. Using a T10 TORX drive head, remove four screws from
4. Note lettering for proper orientation and gently push key- speaker grille. Remove speaker grille from speaker box.
cap onto switch shaft. When orienting keycap, remember
that bottom of assembly is determined by location of 4. Remove speaker from speaker box. Carefully pull two
switch housing rib. socket terminals from speaker spade contacts.

5. Feed Mini-Deutsch socket connector, speaker terminals

and conduit through switch housing hole on outboard INSTALLATION
side of speaker box until switch housing backplate con-
tacts speaker box. Pull harness out through speaker 1. Install two socket terminals onto speaker spade con-
hole. tacts. Different size spade contacts prevent improper
assembly.
6. Reaching into speaker box, align holes in bracket with
holes in switch housing. Using a T25 TORX drive head, 2. With spade contacts at bottom, install speaker in
install two bracket screws. See Figure 8-145. speaker box.
3. Align holes in speaker with those in speaker box. Align
NOTE holes in grille with those in speaker.
To align bracket and switch housing holes, slot in bracket 4. Install four screws. Aternately tighten screws using a
must face toward the front on right side assembly and toward T10 TORX drive head.
the rear on left side. See Figure 8-144. Switch also must be
square in cavity of switch housing or bracket will not fit. 5. Close Tour-Pak.
6. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
7. Feed Mini-Deutsch socket through speaker hole into MAXI-FUSE, INSTALLATION.
speaker box and pull out through harness hole on
inboard side. 7. Test speaker for proper operation.

8. Mate pin and socket halves of Mini-Deutsch connector.

Feed connector back up into speaker box pressing trim
ring into hole.
CB LOADING COIL
9. Install socket terminals onto speaker spade contacts. On
right side of vehicle, install socket terminal of the solid
Green wire onto contact next to the red dot. On left side, REMOVAL
install socket terminal of the solid Brown wire onto con-
tact next to the red dot. 1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
10. Align holes in speaker grille with those in speaker and
slide four TORX screws through grille and speaker 2. Open Tour-Pak. Open map pocket and remove acorn
holes. nuts. Remove map pocket and molded liner from Tour-
Pak.
11. With spade contacts at bottom rear corner, position
3. Disconnect 1-place CB antenna cable connector on right
speaker/grille assembly against speaker box. Thread
side of Tour-Pak. Release cable from rear clip at bottom
four screws into speaker box and tighten using a T10
of Tour-Pak.
TORX drive head.
4. Remove Keps nut, ring terminal and flat washer from
12. Close Tour-Pak. loading coil stud.
13. Install maxi-fuse. See Section 8.3 SYSTEM FUSES, 5. Holding Phillips screw, remove flange nut at bottom of
MAXI-FUSE, INSTALLATION. Tour-Pak to release loading coil bracket. Remove load-
ing coil from vehicle (with Phillips screw, external tooth
14. Test switch for proper operation. lockwasher and flange nut).

2004 Touring: Electrical 8-113

HOME

INSTALLATION AUDIO HARNESS

1. Place new loading coil into position aligning hole in For removal and installation instructions, see Section 8.32
bracket with hole in Tour-Pak. Holding flange nut under WIRING HARNESSES AND CABLES, AUDIO HARNESS
Tour-Pak, install Phillips screw with external tooth lock- (FLHTCU).
washer.

2. Mate pin and socket halves of 1-place CB antenna cable

connector. Capture antenna cable in rear clip at bottom
RADIO ANTENNA CABLE
of Tour-Pak.
For removal and installation, see Section 8.32 WIRING HAR-
3. Install flat washer, ring terminal and Keps nut onto load- NESSES AND CABLES, RADIO ANTENNA CABLE
ing coil stud. Tighten hex nut. (FLHTC/U).

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

secure using acorn nuts. Close Tour-Pak. CB ANTENNA CABLE
5. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION. For removal and installation, see Section 8.32 WIRING HAR-
NESSES AND CABLES, CB ANTENNA CABLE (FLHTCU).
6. Check SWR and adjust if necessary. Follow the SWR
Adjustment procedure in Section 6 of the 2004 ELEC-
TRICAL DIAGNOSTIC MANUAL (Part No. 99497-04).
Remove SWR meter, plug in antenna connector and
tighten antenna connector stud.

8-114 2004 Touring: Electrical

HOME

WIRING HARNESSES AND CABLES 8.32

MAIN HARNESS 6. Repeat steps 4-5 to remove right side saddlebag and
side cover.

NOTE
REMOVAL- ALL MODELS (PART I) Depending upon model, continue procedure at REMOVAL-
FLHR/C/S (PART II), REMOVAL- FLTR (PART II), or
1. Remove fuel tank. For carbureted models, see Section REMOVAL- FLHT/C/U (PART II).
4.7 FUEL TANK (CARBURETED), COMPLETE
REMOVAL, FLHT/C or FLHR/S. For fuel injected mod-
els, see Section 9.4 FUEL TANK (FUEL INJECTED),
COMPLETE REMOVAL, FLHT/C/U/I, FLTRI or FLHR/C/ REMOVAL- FLHR/C/S (PART II)
S/I. 1. Remove the Phillips screw at the bottom of the head-
2. Unthread bolt and remove battery positive cable (red) lamp door (chrome ring). Remove the headlamp door.
from battery positive (+) terminal. (Battery negative 2. Remove the eight Phillips screws to free the headlamp
cable already removed under FUEL TANK, COMPLETE housing from the headlamp nacelle.
REMOVAL.) 3. Squeeze the two external tabs to remove the wire con-
3. Using a T-40 TORX drive head, loosen bolt to move lip of nector at the back of the headlamp bulb. Remove the
hold-down clamp off edge of battery. Remove battery headlamp housing assembly from the motorcycle.
from battery box. 4. See Figure 8-146. Reaching inside the headlamp
nacelle, disconnect main harness as follows:
4. Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL. ● Front fender tip lamp connector [32], 2-place Mul-
tilock (black); used on FLHR only.
5. Gently pull left side cover from frame downtubes (no ● Passing lamps connector [73], 2-place Multilock
tools required). (white); used on FLHR/C only.

f2212x8x Cruise Set/Resume Front Turn

Switch [159] Signals [31]
Used on FLHRC Only Left Handlebar
Controls [24]

Cruise On/Off
Switch [158]
Used on FLHRC Only
Right Handlebar
Controls [22]

Accessory
Switch [67]

Front Fender
Tip Lamp [32]
Passing Lamps Used on FLHR Only
Switch [109]
Used on FLHR/C Only

Headlamp [38]

Passing Lamps [73]

Used on FLHR/C Only

Figure 8-146. Headlamp Nacelle Connectors (FLHR/C/S)

2004 Touring: Electrical 8-115

HOME

f2095x8x
Odometer Ignition/Light
Reset Switch Flexible
Clip Key Switch Connector [33]
Flexible
Clip

Speedometer
Connector [39]

Plastic
Indicator Lights Flexible Clip
Connector [21] Clip

Figure 8-147. Instrument Console Assembly (FLHR/C)

● Passing lamps switch connector [109], 4-place 8. Unthread rubber boot from odometer reset switch and
Amp; used on FLHR/C only. pull switch from hole in instrument console.
● Accessory switch connector [67], 4-place Amp. 9. Bend back flexible clamps on inboard side of instrument
● Right handlebar switch controls connector [22], 6- console as necessary to release main harness conduit.
place Deutsch (black); T-stud on fork stem nut lock Set instrument console aside.
plate (left side).
● Cruise set/resume switch connector [159], 2-place 10. Moving rearward, carefully cut eleven cable straps
Deutsch (black); used on FLHRC only. securing main harness to frame backbone and right and
left frame tubes. See Figure 8-148.
● Front turn signal lamps connector [31], 6-place Mul-
tilock; anchor in hole of fork stem nut lock plate (left
NOTE
side).
● Left handlebar switch controls connector [24], 6- Continue procedure at REMOVAL- ALL MODELS (PART III).
place Deutsch (gray); T-stud on fork stem nut lock
plate (left side).
● Cruise on/off switch connector [158], 2-place Deut-
sch (gray); used on FLHRC only. REMOVAL- FLTR (PART II)
5. Carefully pull main harness rearward under right side of 1. Remove the inner fairing. See Section 2.30 UPPER
headlamp nacelle allowing conduit and connectors to FAIRING/WINDSHIELD (FLTR), INNER FAIRING,
hang over top of engine guard. REMOVAL, steps 1-18.
6. Remove screw and P-clamp to release main harness 2. Remove screw, two main harness ground ring terminals
from right side of steering head. and P-clamp to release main harness bundle from right
side of steering head.
7. See Figure 8-147. Moving to inboard side of instrument
console, disconnect main harness as follows: 3. Moving rearward, carefully cut eleven cable straps
● Ignition/Light Key Switch connector [33], 3-place securing main harness to frame backbone and right and
Packard. left frame tubes. See Figure 8-148.
● Indicator lights connector [21], 8-place Mini-Deut-
NOTE
sch.
● Speedometer connector [39], 12-place Packard. Continue procedure at REMOVAL- ALL MODELS (PART III).

8-116 2004 Touring: Electrical

HOME

2. See Figure 8-149. Disconnect main harness from inter-

connect harness as follows:

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

Backbone place Deutsch (black); T-stud at front of right fairing
1 bracket.
● Main to interconnect harness connector [2], 12-
place Deutsch (gray); T-stud on right fairing support
2A brace.
3A
● Main to interconnect harness connector [15], 4-
place Packard (black); anchor in hole at bottom of
radio (right side).
9A 4A ● Main to interconnect harness connector [156], 6-
place Deutsch (gray); T-stud on right fairing support
brace.

3. See Figure 8-149. Disconnect ignition switch from main

10 A 5A harness. Disconnect radio antenna cable. Proceed as
follows:
● Ignition switch connector [33], 4-place Packard
(black); anchor in hole at bottom of radio (center).
● Radio antenna cable connector [51]; back of radio
11 A 6A
(left side).
Saddlebag
12 7 Guard 4. Remove screw to release main harness ground ring ter-
minal and brake line P-clamp from front of upper fork
bracket.
13 5. Carefully pull main harness rearward under right side of
8 fairing cap allowing conduit and connectors to hang over
f2225x8x top of engine guard.
6. Remove screw, main harness ground ring terminal and
P-clamp to release main harness (and audio harness on
1 Captures main harness, cruise roll-off switch conduit, FLHTCU models) from right side of steering head.
audio harness (FLHTCUI only) and frame backbone.
2 Captures ignition/EFI harness only. ANCHORED. 7. Moving rearward, carefully cut eleven cable straps
3 Captures main harness and audio harness (FLHTCUI securing main harness to frame backbone and right and
only). ANCHORED. left frame tubes. See Figure 8-148. Carefully cut any
4 5 6 Captures main harness, audio harness (FLHTCUI only), cable straps securing main harness to audio harness.
EFI/ignition harness, and conduit to fuel tank harness (all
models except FLHR/C/S). ANCHORED.
NOTE
7 8 Captures audio harness (FLHTCUI only) and upper frame
tube. Continue procedure at REMOVAL- ALL MODELS (PART III).
9 10 Captures main harness and audio harness (FLHTCUI
only). ANCHORED.
11 Captures main harness, audio harness (FLHTCUI only),
fuel vapor vent tube and console pod or instrument
console conduit. ANCHORED. REMOVAL- ALL MODELS (PART III)
12 Captures main harness, audio harness (FLHTCUI only),
console pod or instrument console conduit and upper
1. If cruise equipped, locate the cruise control roll-off
frame tube. switch plumbed into the idle cable on right side of the
13 Captures main harness, audio harness (FLHTCUI only), steering head. Push rubber boot on switch forward and
console pod conduit (FLHTCUI only) and upper frame remove socket terminals from spade contacts.
tube.
2. Moving to left side of motorcycle, remove acorn nut to
release horn bracket from rubber mount stud. Pull elbow
Figure 8-148. Cable Strap Locations terminals from spade contacts on horn and release con-
duit from J-clamp.
3. Remove flange nut (10 mm) from left side ground stud
REMOVAL- FLHT/C/U (PART II) on upper frame crossmember. Remove two main har-
ness ground ring terminals. Repeat step to remove two
1. Remove the outer fairing and windshield. See Section main harness ground ring terminals from right side
2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), ground stud.See Figure 8-150.
OUTER FAIRING/WINDSHIELD, REMOVAL.

2004 Touring: Electrical 8-117

HOME

Main to Interconnect
f2238x8x
Harness [15]

Main to Interconnect
Main to Interconnect Harness [156]
Harness [2]

Main to Interconnect
Harness [1]

Radio Antenna
Cable [51]
Ignition
Switch [33]

Figure 8-149. Inner Fairing - Main Harness Connectors (FLHTC/U)

4. Depress latches on maxi-fuse holder and then slide 9. Disconnect the rear fender lights connector [7], 8-place
cover rearward to disengage tongue from groove in fuse Multilock, anchored at front of rear fender. Detach pin
block cover. housing from anchor.
5. Moving to right side of motorcycle, pull back boot at top 10. Release ignition keyswitch and starter relays by pulling
of starter housing and remove flange nut and main anchors on rubber molding from holes in frame weld-
power cable ring terminal from post. Release cable from ment at rear of battery box. Remove relays and molding
clip anchored to T-stud at front of battery tray. Draw main from connectors. Push connectors down into space
power cable to left side of motorcycle. below frame weldment.
6. Carefully cut anchored cable strap to release fuse block 11. Locate the turn signal/security module inside hole of
conduit from fuse block bracket. Pull fuse block from frame weldment on opposite side. Depress tab at front of
tabs on bracket. spring clip and lift to release legs from holes in weld-
7. Remove the fuse block cover. Raise lipped side slightly ment. Remove module and disconnect 12-place Deut-
to disengage slots from tabs on fuse block. sch connector [30]. Push connector down into space
below frame weldment.
8. If cruise equipped, lift the locking latch and remove
cruise module connector [17]. From inside battery box, 12. Pull rear fender lights, ignition keyswitch and starter
remove three flange bolts. Carefully pull cruise module relays, and turn signal/security module conduit and con-
away from side of battery box exercising caution to avoid nectors out through opening above rear of fuse block
losing grommets. bracket and allow to hang on left side of motorcycle.

8-118 2004 Touring: Electrical

HOME

13. Depending upon model, proceed as follows: FLHTCU: Open map pocket and remove acorn nuts
FLHR/C/S: Move to step 14. with flat washers. Remove map pocket and molded
liner from Tour-Pak.
FLTR:
b. Depress external latch and remove bulb socket from
a. On left side of motorcycle, remove bolt (with flat left side of Tour-Pak.
washer) to remove passenger seat strap and sad-
dlebag front mounting bracket. Remove Phillips c. Rotate knurled ring in a counterclockwise direction
screw and chrome frame tube cover. to separate pin and socket halves of radio antenna
cable connector [51]. Release cable from two clips
b. Carefully cut cable strap to release radio antenna at bottom of Tour-Pak.
cable from shoulder of upper frame tube (just in
front of air valve mounting bracket). Cut cable strap d. On FLHTCU models, depress button and separate
to release radio antenna cable from slotted hole in pin and socket halves of Tour-Pak lights connector
rear fender support. [12], 3-place Multilock, inside Tour-Pak.

c. At bottom of radio antenna bracket, rotate knurled e. Pull grommet into Tour-Pak and remove from main
ring to separate pin and socket halves of radio harness conduit.
antenna cable connector [51]. f. Pull Tour-Pak lights and radio antenna cable con-
d. Draw radio antenna cable forward to area of fuse nectors through hole at front of Tour-Pak. Cut cable
block bracket and allow to hang with other main har- strap to release conduit from luggage rack rail.
ness branches. g. Draw Tour-Pak lights and radio antenna cable con-
nectors forward to area of fuse block bracket and
FLHTC/U:
allow to hang with other main harness branches.
a. Open Tour-Pak and proceed as follows: Remove flange nuts to release passenger hand rail,
FLHTC: Remove rubber mat. if necessary.

f2250x8x
Main Harness
Ground Ring
Terminals (2)

Main Harness
Ground Ring
Terminals (2)
Chassis
Ground Cable

Fuel Tank Harness Accessory

Connector [13] Connector [4]
Not Present on FLHR/C/S

Battery
Positive Cable

B+ Connector [160] Battery

Negative Cable

Figure 8-150. Electrical Connectors - Upper Frame Cross Member (Under Seat)

2004 Touring: Electrical 8-119

HOME

f2276x8x

Battery
Anchored Cable Strap Box
See Figure 8-150.
Captures Main Harness Conduit,
Neutral Switch Conduit and
Vehicle Speed Sensor Cable

6 Cable Strap
Captures Main Harness Conduit,
Voltage Regulator Cables and
Cable Strap Lower Frame Tube
Captures Main Harness Conduit
and Frame Downtube 5

3
2

4 1

Cable Strap Cable Strap Anchor Cable Strap Anchor

Captures Rear Brake Light Switch Wires
and Lower Frame Tube Captures Main Harness Conduit Captures Main Harness Conduit,
and Rear Brake Line Voltage Regulator Cables and
Rear Brake Line

Figure 8-151. Cable Straps (Right Side View)

14. Cut anchored cable strap to release accessory connec- 19. Cut cable strap to free voltage regulator cables and main
tor [4] and B+ connector [160] from left side of frame harness conduit (leading to oil pressure sender and
crossmember (in front of battery box). See Figure 8-150. crankshaft position sensor connectors) from inboard
15. Cut cable strap to release vapor valve from mounting side of rear brake pedal weldment. See Figure 8-151.
bracket. Move vapor valve out of the way to facilitate har- 20. Cut cable straps from two anchors installed on T-studs at
ness removal. top of lower frame tube.
16. Alternately feed branches of main harness hanging on 21. Locate voltage regulator connector [77], 1-place Deut-
left side of motorcycle into battery box through opening sch, just below the transmission exhaust bracket.
above front of fuse block bracket. For best results, feed Depress external latch to separate pin and socket hous-
one length of conduit through at a time drawing the fuse ings.
block through the opening last. Pulling branches out of
battery box, allow conduit and connectors to hang on left 22. Depress external latch and pull solenoid connector from
side of frame backbone. top of starter housing.
17. Moving to front right side of motorcycle, locate crank- 23. Remove two elbow connectors from neutral switch
shaft position sensor connector [79], 2-place Mini-Deut- posts.
sch, fixed to bracket at bottom of voltage regulator. Push
connector toward right side of motorcycle to disengage 24. Pull two socket terminals from spade contacts on rear
small end of slot on attachment clip from T-stud on brake light switch. Cut cable strap to free rear brake light
bracket. Lift connector off T-stud. Depress button on switch wires from lower frame tube.
socket terminal side and pull apart pin and socket 25. Cut cable strap at rear of rear brake light switch bracket
halves. to release main harness conduit from frame downtube.
18. Locate oil pressure sender at the front right side of the
crankcase. On FLHR/C/S models, pull elbow from post 26. Cut anchored cable strap in hole of frame downtube
of oil pressure switch. On FLHT/C/U and FLTR models, (inboard of rear swingarm bracket) to release vehicle
pull external latch outward and use rocking motion to speed sensor cable, main harness and neutral switch
remove Packard connector from oil pressure sender. conduit.

8-120 2004 Touring: Electrical

HOME

27. Pull ignition/EFI harness connector [8] from slot in elec-

trical bracket. Depress external latches and separate pin
and socket halves.

28. Remove two flange nuts to release electrical bracket

from studs on side of battery box. Release security siren
connector and conduit from inboard side of electrical
bracket.

29. Pull ignition/EFI harness connector [8] and security siren

connector [142] and conduit into battery box through
opening at rear of frame crossmember.

30. Draw neutral switch wires out from under starter hous-
ing. For best results, move electrical bracket out of the
way and reach in under right side of battery box.

31. Carefully pull rear brake light switch, starter solenoid, 8319

and neutral switch conduit and connectors rearward and

then feed up into battery box through same opening at Figure 8-152. Feed Harness Into Battery Box (Right Side)
rear of frame crossmember. See Figure 8-152.

32. Note that main harness runs forward of the front battery
8321
box TORX screw. Pull harness to the rear of the screw,
and then draw conduit and connectors out of battery box
and allow to hang on right side of frame backbone. See
lower frame of Figure 8-153.

CAUTION

Damage to wires can result in electrical problems. Be

sure that rubber boot is present on threaded end of bat- Rubber
tery box TORX screw. Replace rubber boot if absent or Boot
damaged. See upper frame of Figure 8-153.

33. Remove main harness from motorcycle.

INSTALLATION- ALL MODELS (PART I) Figure 8-153. Battery Box TORX Screw (Right Side)

NOTE
NOTE
Disregard references to radio antenna cable and starter relay
If reusing the main harness, thread new cable strap through
connectors when working on FLHR/C/S models. The connec-
eye in anchor and loosely capture main harness bundle. If
tors are not part of the main harness on these motorcyles.
installing a new harness, remove and discard old anchor and
plug anchor attached to new harness into hole in center of
1. Position main harness on motorcycle as follows:
frame backbone.
a. Lay main harness on frame backbone so that front
Left Side
branches hang over top of right engine guard. On
FLHR/C/S models, front branches terminate in c. Locate left side branch terminating in rear fender
headlamp and handlebar switch control connectors lights, ignition keyswitch and starter relays, turn sig-
(see Figure 8-146). On FLTR and FLHT/C/U mod- nal/security module, fuse block, cruise module (if
els, front branches terminate in the ignition switch, equipped) and radio antenna cable connectors.
radio antenna cable and interconnect harness con- Feed connectors and conduit into battery box pull-
nectors (see Figure 8-149). ing branches out through opening above front of
fuse block bracket. Continue drawing harness out
b. Adjust harness so that left and right side branches through opening until two main harness ground ring
split from main branch at location of anchor at cen- terminals are adjacent to left side ground stud on
ter of frame backbone. frame crossmember.

2004 Touring: Electrical 8-121

HOME

d. Feed rear fender lights, ignition keyswitch and 8. Slide cover over fuse block until slots fully engage tabs
starter relays, and turn signal/security module con- on block. Slide fuse block into position on mounting
duit and connectors through opening above rear of bracket. Tabs on bracket fit into slots on each side of
fuse block bracket to area in front of rear fender. fuse block cover. Install new anchored cable strap in
hole at rear of fuse block bracket. Tighten cable strap to
NOTE capture fuse block conduit.
On FLTR and FLHT/C/U models, leave longer conduit of
radio antenna cable hanging outboard of fuse block bracket. 9. Route main power cable on maxi-fuse holder through
opening above front of fuse block bracket and then for-
Right Side ward passing under frame crossmember toward right
side of motorcycle. Pull back boot at top of starter hous-
e. Feed right side connectors and conduit into battery
ing and install ring terminal on post. Install flange nut
box pulling voltage regulator, oil pressure sender
and tighten to 70-90 in-lbs (7.9-10.2 Nm). Capture cable
and crankshaft position sensor connectors and con-
in clip anchored to T-stud at front of battery tray.
duit out through opening at rear of frame cross-
member. Feed connectors and conduit forward and
then downward following front of frame downtube. 10. Returning to left side of motorcycle, slide maxi-fuse
Continue drawing harness out through opening in cover forward to engage tongue in groove of fuse block
side of battery box until two main harness ground cover and then insert maxi-fuse holder into cover until
ring terminals are adjacent to right side ground stud latches engage.
on frame crossmember.
11. Install new anchored cable strap in lower hole on left
side of frame crossmember (in front of battery box).
2. Returning to left side of motorcycle, route horn conduit in
Tighten cable strap to capture conduit of both accessory
front of the top stabilizer link and then under the top
connector [4] and B+ connector [160] approximately one
engine mounting bracket to back of horn. Install elbow
inch from connector housings. See Figure 8-150.
terminals onto horn spade contacts. Capture conduit in
J-clamp. Slide horn bracket onto rubber mount stud and
install acorn nut with flat washer. Tighten acorn nut to 12. Hold vapor valve in position on left side of mounting
80-100 in-lbs (9.0-11.3 Nm). bracket. From right side of bracket, insert end of small
cable strap through hole in arm and then around body of
3. Slide two main harness ground ring terminals onto left vapor valve. Mate ends of cable strap and pull tight
side ground stud on upper frame crossmember and engaging strap in slot of arm. Cut any excess cable strap
install flange nut (10 mm). Install chassis ground ring ter- material.
minal onto right side ground stud and then two main har-
ness ground ring terminals and flange nut (10 mm). 13. Depending upon model, proceed as follows:
Tighten flange nuts to 50-90 in-lbs (5.7-10.2 Nm). See
Figure 8-150. FLHR/C/S: Move to step 14.
4. Mate pin and socket halves of rear fender lights connec-
tor [7], 8-place Multilock, and attach to anchor at front of FLTR:
rear fender.
a. Feed radio antenna cable and connector rearward
5. At front of rear fender, feed ignition keyswitch and starter following inboard side of upper frame tube. With the
relay connectors up through rectangular shaped hole in 3-place Multilock connector (unused) positioned
frame weldment. Fit relay connectors into rubber mold- about as far rearward as the rear shock air valve,
ing and install anchors on molding into holes in frame install new cable strap to secure radio antenna
weldment. Install relays in connectors. cable to shoulder of upper frame tube (just in front
6. Feed turn signal/security module connector [30] up of air valve mounting bracket). Using slotted hole,
through hole on opposite side of frame weldment and install new cable strap to secure radio antenna
connect to module. Install module into hole in frame cable to rear fender support. See Figure 8-154.
weldment. Insert legs of spring clip into holes in weld-
ment and push down until tab at front snaps in place. b. At bottom of radio antenna bracket, rotate knurled
ring to mate pin and socket halves of radio antenna
7. If cruise equipped, install grommets into holes on left cable connector [51].
side of battery box with the larger OD on the outboard
side. Align threaded holes on inboard side of cruise
c. Install chrome frame tube cover on frame tube.
module with holes in grommets and install flange bolts
Install Phillips screw. Install bolt (with flat washer) to
from inside battery box. Alternately tighten flange bolts
fasten saddlebag front mounting bracket and pas-
to 60-96 in-lbs (6.8-10.9 Nm). Install cruise module con-
senger seat strap to chrome frame tube cover.
nector [17] and engage locking latch.

8-122 2004 Touring: Electrical

HOME
16. Snap solenoid connector to terminal at top of starter
1 9425 housing.
17. Install new anchored cable strap in hole of frame down-
tube (inboard of rear swingarm bracket) capturing vehi-
cle speed sensor cable, main harness and neutral switch
conduit. See Figure 8-151.
18. Install new cable strap at rear of rear brake light switch
bracket capturing main harness conduit and frame
downtube. Cut any excess cable strap material.
19. Install two socket terminals onto spade contacts of rear
brake light switch. Install new cable strap to secure rear
brake light switch wires to lower frame tube.
20. Route branch of the main harness (terminating in the
voltage regulator, oil pressure sender and crankshaft
2 position sensor connectors) forward to front of motorcy-
cle following inboard side of lower frame tube.

Figure 8-154. Capture Radio Antenna Cable (FLTR) 21. Mate pin and socket housings of voltage regulator con-
nector [77], 1-place Deutsch, just below the transmission
exhaust bracket.

FLHTC/U: 22. Position main harness conduit over two anchors

installed on T-studs at top of lower frame tube. Thread
a. Feed Tour-Pak lights and radio antenna cable con- new cable straps through eyelets in anchors to capture
nectors and conduit through hole at front of Tour- conduit. Cut any excess cable strap material.
Pak. Capture cable and conduit in grommet. Install
grommet in hole with the larger OD facing inside. NOTE
b. Mate pin and socket halves of Tour-Pak lights con- In addition to the main harness conduit, rear cable strap
nector [12], 3-place Multilock, and tuck into cavity anchor also captures rear brake line, while front anchor cap-
inside Tour-Pak. tures rear brake line and voltage regulator cables.
c. Rotate knurled ring in a clockwise direction to mate 23. Route main harness conduit inboard of rear brake pedal
pin and socket halves of radio antenna cable con- weldment. Capturing main harness conduit and lower
nector [51]. Capture cable in two clips at bottom of frame tube, install new cable strap through opening in
Tour-Pak. rear brake pedal weldment. See Figure 8-151. Cut any
d. Install bulb socket on left side of Tour-Pak. excess cable strap material.

e. Loosely install new cable strap to secure main har- NOTE

ness conduit to luggage rack rail.
Cable strap also captures voltage regulator cables.
f. Proceed as follows:
FLHTC: Install rubber mat in Tour-Pak. Close Tour- 24. Route oil pressure sender and crankshaft position sen-
Pak. sor connectors upward at rear of lower frame crossmem-
ber.
FLHTCU: Install molded liner in Tour-Pak. Install
map pocket and secure using acorn nuts (with flat 25. Mate pin and socket halves of crankshaft position sensor
washers). Close Tour-Pak. connector [79]. Place large end of slot on attachment
clip over T-stud on bracket at bottom of voltage regulator.
Push connector toward left side of motorcycle to engage
14. Returning to right side of motorcycle, feed voltage regu-
small end of slot.
lator, oil pressure sender and crankshaft position sensor
connectors and conduit downward between rear swing- 26. Install the oil pressure sender connector at the front right
arm and oil filler spout until free ends hang below lower side of the crankcase. On FLHR/C/S models, install
frame tube. elbow connector on post terminal. On FLHT/C/U and
FLTR models, install 4-place Packard connector.
15. Route neutral switch wires under starter housing to
transmission top cover. For best results, move electrical 27. Returning to area of electrical bracket, feed ignition/EFI
bracket out of the way and reach in under right side of harness connector [8] and security siren connector [142]
battery box. Install two elbow connectors onto posts of and conduit through opening to outboard side of battery
neutral switch. box.

2004 Touring: Electrical 8-123

HOME

28. Route siren connector and conduit on inboard side of 5. See Figure 8-146. Connect main harness as follows:
electrical bracket and install bracket on studs at side of
● Front fender tip lamp connector [32], 2-place Mul-
battery box. Install flange nuts on studs and tighten to
tilock (black); used on FLHR only.
36-48 in-lbs (4.1-5.4 Nm).
● Passing lamps connector [73], 2-place Multilock
29. Mate pin and socket halves of ignition/EFI harness con- (white); used on FLHR/C only.
nector [8]. Install connector into slot of electrical bracket.
● Passing lamps switch connector [109], 4-place
30. Pull up on main harness and tuck conduit into space in Amp; used on FLHR/C only.
front of the battery box TORX screw (along with ignition/
● Accessory switch connector [67], 4-place Amp.
EFI harness). See lower frame of Figure 8-153.
● Right handlebar switch controls connector [22], 6-
place Deutsch (black); T-stud on fork stem nut lock
CAUTION plate (left side).
Damage to wires can result in electrical problems. Be ● Cruise set/resume switch connector [159], 2-place
sure that rubber boot is present on threaded end of bat- Deutsch (black); used on FLHRC only.
tery box TORX screw. Replace rubber boot if absent or ● Front turn signal lamps connector [31], 6-place Mul-
damaged. See upper frame of Figure 8-153. tilock; anchor in hole of fork stem nut lock plate (left
side).
31. At front of top engine stabilizer bracket, install new 14
inch cable strap capturing frame backbone and main ● Left handlebar switch controls connector [24], 6-
harness bundle. Tighten cable strap, but leave loose place Deutsch (gray); T-stud on fork stem nut lock
enough so that one finger can be inserted between strap plate (left side).
and frame backbone. Do not overtighten. Cut any ● Cruise on/off switch connector [158], 2-place Deut-
excess cable strap material. sch (gray); used on FLHRC only.
32. If cruise equipped, install cruise roll-off switch as follows: 6. Install the wire connector at the back of headlamp bulb.
a. Separate the cruise roll-off switch wires up to the
7. Align holes in headlamp housing with those in headlamp
point where they enter the main harness conduit.
nacelle (headlamp door bracket at bottom). Install the
b. Orient the idle cable so that the spade contacts are eight Phillips screws.
at the top.
8. Fit the square-shaped portion of the headlamp door
c. Slide the insulators onto the switch spade contacts spring into the slot at the top of the headlamp housing
(polarity is not a factor). For maximum insertion, be and then snap the headlamp door (chrome ring) into
sure that the external step on the insulators face place. Install Phillips screw at the bottom of the head-
each other. lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).
d. Fit the rubber boot over the cruise control roll-off 9. See Figure 8-147. Moving to inboard side of instrument
switch. An oval cut in the boot accommodates the console, connect main harness as follows:
switch spade terminal connections.
● Ignition/light key switch connector [33], 3-place
NOTE Packard.
Depending upon model, continue procedure at INSTALLA- ● Indicator lights connector [21], 8-place Mini-Deut-
TION- FLHR/C/S (PART II), INSTALLATION- FLTR (PART sch.
II), or INSTALLATION- FLHT/C/U (PART II). ● Speedometer connector [39], 12-place Packard.

10. Slide odometer reset switch through hole in instrument

console and install rubber boot.
INSTALLATION- FLHR/C/S (PART II)
11. Bend flexible clamps on inboard side of instrument con-
1. Install remaining cables straps as shown in Figure 8- sole as necessary to capture main harness conduit.
148.
NOTE
2. Carefully feed main harness conduit and connectors for-
ward under right side of instrument nacelle (keeping out- Continue procedure at INSTALLATION- ALL MODELS
board of the front brake line). (PART III).
3. Install P-clamp on main harness bundle. Install screw to
fasten P-clamp to right side of steering head.
4. Moving to front of motorcycle, reach inside headlamp INSTALLATION- FLTR (PART II)
nacelle and install screw to fasten harness ground ring
terminal and brake line P-clamp to front of upper fork 1. Install remaining cables straps as shown in Figure 8-
bracket. 148.

8-124 2004 Touring: Electrical

HOME

2. Install P-clamp on main harness bundle. Install two main INSTALLATION- ALL MODELS (PART III)
harness ground ring terminals onto screw and fasten P-
clamp to right side of steering head. 1. Place battery in battery box, terminal side forward.
3. Install the inner fairing. See Section 2.30 UPPER FAIR- Rotate hold-down clamp so that lip (with rubber pad)
ING/WINDSHIELD (FLTR), INNER FAIRING, INSTAL- rests on edge of battery and tighten clamp bolt.
LATION, steps 3-20.

NOTE 1WARNING
Continue procedure at INSTALLATION- ALL MODELS Always connect the positive battery cable first. If the
(PART III). positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.

INSTALLATION- FLHT/C/U (PART II) 2. Insert bolt through battery positive cable (red) into
threaded hole of battery positive (+) terminal. Tighten
1. Install remaining cables straps as shown in Figure 8- bolt to 60-96 in-lbs (6.8-10.9 Nm).
148.
3. Insert bolt through battery negative cable (black) into
2. Install P-clamp on main harness (and audio harness on
threaded hole of battery negative (-) terminal. Tighten
FLHTCU models). Install main harness ground ring ter-
bolt to 60-96 in-lbs (6.8-10.9 Nm).
minal onto screw and fasten P-clamp to right side of
steering head. 4. Align barbed studs in left side cover with grommets in
3. Moving to right engine guard, carefully feed main har- frame downtubes and push firmly into place (no tools
ness conduit and connectors forward under right side of required).
fairing cap to front of inner fairing.
5. Install left side saddlebag. See Section 2.25 SADDLE-
4. Install screw to fasten harness ground ring terminal and BAG, INSTALLATION.
brake line P-clamp to front of upper fork bracket.
6. Repeat steps 4-5 to install right side saddlebag and side
5. See Figure 8-149. Standing at front of motorcycle, mate cover.
pin and socket halves of the following connectors and fix
positions using retaining devices: 7. Install fuel tank. For carbureted models, see Section 4.7
FUEL TANK (CARBURETED), INSTALLATION (AFTER
● Main to interconnect harness connector [1], 12-
COMPLETE REMOVAL), FLHT/C or FLHR/S. For fuel
place Deutsch (black); T-stud at front of right fairing
injected models, see Section 9.4 FUEL TANK (FUEL
bracket.
INJECTED), INSTALLATION (AFTER COMPLETE
● Main to interconnect harness connector [2], 12- REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.
place Deutsch (gray); T-stud on right fairing support
brace.
● Main to interconnect harness connector [15], 4-
place Packard (black); anchor in hole at bottom of
radio (right side). FRAME GROUND STUD
● Main to interconnect harness connector [156], 6- REPLACEMENT
place Deutsch (gray); T-stud on right fairing support
brace.
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
6. See Figure 8-149. Connect ignition switch to main har-
ness. Connect radio antenna cable. Proceed as follows: 2. Locate threaded hole between ground studs. See Figure
8-155. Thoroughly scrape away all paint from around
● Ignition switch connector [33], 4-place Packard threaded hole.
(black); anchor in hole at bottom of radio (center).
● Radio antenna cable connector [51]; back of radio 3. Moving to front of frame crossmember, thoroughly
(left side). scrape away all paint on face of threaded boss.

7. Install the outer fairing and windshield. See Section 2.29 4. Obtain five parts shown in Figure 8-156.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
5. Start hex screw into threaded boss and tighten to 90-120
FAIRING/WINDSHIELD, INSTALLATION.
in-lbs (10.2-13.6 Nm).
NOTE 6. At rear of frame crossmember, install flat washer and
Continue procedure at INSTALLATION- ALL MODELS lockwasher onto threaded end of hex screw. Install hex
(PART III). nut and tighten to 90-120 in-lbs (10.2-13.6 Nm).

2004 Touring: Electrical 8-125

HOME

7. If replacing left side ground stud, slide two main harness

Threaded Hole ground ring terminals onto hex screw. If replacing right
side ground stud, install chassis ground ring terminal
before the two main harness grounds.

8. Install jam nut onto hex screw and tighten to 50-90 in-
lbs (5.7-10.2 Nm).

9. Install seat. See Section 2.24 SEAT, INSTALLATION.

f2250x8x

Figure 8-155. Remove Seat

Harness Ground
Ring Terminals Frame
3 Crossmember

5
4
2 Boss

1. Hex Screw, 2551W

2. Flat Washer, 6703 4. Hex Nut, 7688
3. Lock Washer, 7036 5. Jam Nut, 7689W

Figure 8-156. Install New Frame Ground Stud

8-126 2004 Touring: Electrical

HOME

INTERCONNECT HARNESS f2254x8x

(FLHTCU)

REMOVAL
NOTE
When referencing inner fairing locations, the term “fairing
bracket” refers to either the left or right vertical support, while
the term “support brace” refers to either the left or right hori-
zontal support. References to left and right always refers to
left and right side of motorcycle.
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Remove the outer fairing and windshield. See Section
2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL.
3. Release anchors on convoluted tubing of interconnect Figure 8-157. Anchor Interconnect Harness in Lower
harness from lower outboard ears of speedometer and Ears of Speedometer/Tachometer Brackets
tachometer brackets. See Figure 8-157. For best results,
squeeze anchor with needle nose pliers before pulling
from hole in ear.
g. Ambient temperature sensor connector [107], if
4. Remove anchor on convoluted tubing of headlamp con- present; 3-place Multilock (black); anchor in hole on
nector from hole in left fairing bracket. See Figure 8-160. outboard side of left fairing bracket.
5. On opposite side of inner fairing, remove anchor on con-
duit of fairing cap switch connector from hole in lower h. Left handlebar switch controls connector [24], 12-
wing of right side radio support bracket. See Figure 8- place Deutsch (gray); T-stud on top of left fairing
161. support brace (inboard side).
6. Cut cable strap to release convoluted tubing of intercon-
i. Front turn signal connector [31], 6-place Multilock
nect harness, conduit of main to interconnect harness
(black); T-stud on top of left fairing support brace
connectors [2] and [156], and housing of main to inter-
(outboard side).
connect harness connector [1] from right fairing bracket.
See Figure 8-162.
j. Main to interconnect harness connector [1], 12-
7. Remove connectors from their retaining devices, if place Deutsch (black); T-stud at front of right fairing
present, and disconnect pin and socket halves. See Fig- bracket.
ure 8-158.
a. Main to interconnect harness connector [2], 12- k. Main to interconnect harness connector [15], 4-
place Deutsch (gray); T-stud on right fairing support place Packard (black); anchor in hole at bottom of
brace (outboard side). radio (right side).

b. Main to interconnect harness connector [156], 6- l. Fairing cap switch connector [105], 12-place Mul-
place Deutsch (gray); T-stud on right fairing support tilock (black); top of upper fork bracket (right side).
brace (inboard side).
c. Radio connector [27], 23-place Amp (black); back of m. Right handlebar switch controls connector [22], 12-
radio (right side). place Deutsch (black); T-stud on fork stem nut lock
plate (left side).
d. Indicator lamps [21]; 10-place Multilock (black);
above radio (between speedometer and tachometer n. Audio to interconnect harness connector [6], if
gauges). present; 3-place Deutsch (black); back of radio.
e. Speedometer connector [39]; 12-place Packard
(black); back of speedometer. Unthread rubber boot o. Passing lamps connector [73], 2-place Multilock
from odometer reset switch and pull switch from (white); below upper fork bracket (left side).
hole in inner fairing.
p. Front fender tip lamp connector [32], 2-place Mul-
f. Tachometer connector [108]; 12-place Packard
tilock (black); below upper fork bracket (left side).
(gray); back of tachometer.

2004 Touring: Electrical 8-127

HOME

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]

Passing
Lamp [73]

Right Handlebar
Switch Controls [22]
f2238x8x

Figure 8-158. Inner Fairing - Interconnect Harness Connectors (FLHTC/U)

8. See Figure 8-159. 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-
Left side: nal connectors to mid section of inner fairing (area
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

8-128 2004 Touring: Electrical

HOME

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 8-159. 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 8-159. Remove connectors from spade con-
tacts as follows: When referencing inner fairing locations, the term “fairing
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 8-157.
● 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

2004 Touring: Electrical 8-129

HOME

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 8-160. 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.
9. Install connectors onto spade contacts as follows: Anchor

Right side:
● Right speaker Oval Shaped
● Voltmeter gauge and lamp Hole

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 8-161. 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
gauges). Cable
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 8-162. Cable Strap Convoluted Tubing, Conduit
boot.
and Connector to Fairing Bracket

8-130 2004 Touring: Electrical

HOME

f. Tachometer connector [108]; 12-place Packard 13. On opposite side of inner fairing, install anchor on con-
(gray); back of tachometer. duit of fairing cap switch connector into hole in lower
wing of right side radio support bracket. See Figure 8-
g. Ambient temperature sensor connector [107], if
161.
present; 3-place Multilock (black); anchor in hole on
outboard side of left fairing bracket. 14. Using oval shaped hole in right fairing bracket, install
new cable strap capturing convoluted tubing of intercon-
h. Left handlebar switch controls connector [24], 12-
nect harness, conduit of main to interconnect harness
place Deutsch (gray); T-stud on top of left fairing
connectors [15] and [156], and housing of main to inter-
support brace (inboard side).
connect harness connector [1]. See Figure 8-161 and
i. Front turn signal connector [31], 6-place Multilock Figure 8-162.
(black); T-stud on top of left fairing support brace
15. Install the windshield and outer fairing. See Section 2.29
(outboard side).
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
j. Main to interconnect harness connector [1], 12- FAIRING/WINDSHIELD, INSTALLATION.
place Deutsch (black); T-stud at front of right fairing
16. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
bracket.
MAXI-FUSE, INSTALLATION.
k. Main to interconnect harness connector [15], 4-
place Packard (black); anchor in hole at bottom of
radio (right side).
l. Fairing cap switch connector [105], 12-place Mul-
tilock (black); top of upper fork bracket (right side).
m. Right handlebar switch controls connector [22], 12-
place Deutsch (black); T-stud on fork stem nut lock
plate (left side).
n. Audio to interconnect harness connector [6], if
present; 3-place Deutsch (black); back of radio.
o. Passing lamps connector [73], 2-place Multilock
(white); below upper fork bracket (left side).
p. Front fender tip lamp connector [32], 2-place Mul-
tilock (black); below upper fork bracket (left side).

12. Install anchor on convoluted tubing of headlamp connec-

tor into hole in left fairing bracket. See Figure 8-160.

2004 Touring: Electrical 8-131

HOME

INTERCONNECT HARNESS (FLTR) 5. See Figure 8-163. Disconnect main harness from inter-
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).
● Main to interconnect harness connector [15], 4-
2. Place protective material on top of front fender to protect
place Packard (black); below radio (right side).
paint from scratches or other damage.
● Main to interconnect harness connector [156], 6-
3. Remove the outer fairing and windshield. See Section
place Deutsch (gray); below radio (right side).
2.30 UPPER FAIRING/WINDSHIELD (FLTR), OUTER
FAIRING, REMOVAL.
6. See Figure 8-163. Disconnect handlebar switch controls
4. Carefully cut two cable straps and allow wire bundles from interconnect harness. Disconnect radio and radio
and conduit to hang naturally. See Figure 8-165. 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 8-163. Inner Fairing Connections (FLTR)

8-132 2004 Touring: Electrical

HOME

Indicator Instrument Nacelle

f2219x8x Switches [105]
Lamps [21]

Tachometer
Gauge [108]
Speedometer
Gauge [39]

Speaker Ambient
Switch [105] Temperature
Sensor [107]

Figure 8-164. Instrument Nacelle (Bezel Removed)

● Left handlebar switch controls connector [24], 12- to front of inner fairing. Allow the interconnect harness to
place Deutsch (gray); T-stud on left side of radio hang along the left side of the front fender.
bracket.
10. Remove connectors from spade contacts as follows:
● Right handlebar switch controls connector [22], 12-
place Deutsch (black); T-stud on left side of radio Left side:
bracket.
● Left speaker
NOTE
● Fuel gauge and lamp
Push on each handlebar connector to disengage small end
of slot on attachment clip from T-stud on radio bracket. Lift ● Ambient temperature gauge and lamp
connector off T-stud. ● Cigarette lighter
● Radio connector [27], 23-place Amp (black); back of
radio (right side). Right side:
● Radio ground; single spade and socket terminal; ● Right speaker
below radio (left side).
● Voltmeter gauge and lamp
7. Remove left side of instrument nacelle. See Section 2.30
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT ● Oil pressure gauge and lamp
NACELLE, REMOVAL, steps 1-6.
11. Free conduit of front turn signal lamp connectors [31L]
8. See Figure 8-164. Disconnect instrument nacelle and [31R], 3-place Multilocks, from flexible clips on sides
switches and ambient temperature sensor from intercon- of inner fairing.
nect harness as follows:
12. Remove interconnect harness from motorcycle. Remove
● Instrument nacelle switch connector [105], 12-place
radio antenna cable connector [51] at back of radio (left
Multilock.
side) to facilitate removal.
● Ambient temperature sensor connector [107], 3-
place Multilock.
9. See Figure 8-164. Draw branches of interconnect har- INSTALLATION
ness (terminating in odometer reset switch and speed-
ometer, tachometer, indicator lamps, instrument nacelle 1. Center convoluted tubing of interconnect harness above
switch and ambient temperature sensor connectors) and inboard of hooks on radio bracket. See Figure 8-
from instrument nacelle through tunnel of fairing bracket 165. To verify proper orientation, be sure that long length

2004 Touring: Electrical 8-133

HOME
4. See Figure 8-164. Connect instrument nacelle switches
9427 and ambient temperature sensor to interconnect har-
ness as follows:

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

Multilock.
● Ambient temperature sensor connector [107], 3-
place Multilock.

5. See Figure 8-163. Connect handlebar switch controls to

interconnect harness. Connect radio and radio ground.
Proceed as follows:

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

place Deutsch (gray); T-stud on left side of radio
bracket.
1 2
● Right handlebar switch controls connector [22], 12-
place Deutsch (black); T-stud on left side of radio
Figure 8-165. Cable Strap Convoluted Tubing bracket.
and Conduit
NOTE

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

of conduit terminating in socket terminals of cigarette radio bracket and push on each handlebar connector to
lighter is on left side of motorcycle. Install radio antenna engage small end of slot.
cable connector [51] at back of radio (left side), if
removed. ● Radio connector [27], 23-place Amp (black); back of
radio (right side).
2. Install connectors onto spade contacts as follows:
● Radio ground; single spade and socket terminal;
Left side:
below radio (left side).
● Left speaker
● Fuel gauge and lamp 6. See Figure 8-163. Connect main harness to intercon-
● Ambient temperature gauge and lamp nect harness as follows:

● Cigarette lighter; connect the orange/white wire ● Main to interconnect harness connector [1], 12-
socket terminal to the socket spade contact, the place Deutsch (black); below radio (right side).
black wire socket terminal to the shell contact. ● Main to interconnect harness connector [2], 12-
place Deutsch (gray); below radio (right side).
Right side:
● Main to interconnect harness connector [15], 4-
● Right speaker
place Packard (black); below radio (right side).
● Voltmeter gauge and lamp
● Main to interconnect harness connector [156], 6-
● Oil pressure gauge and lamp place Deutsch (gray); below radio (right side).
Left side:
7. Orient connectors as shown in Figure 8-163. Install two
● Left speaker new cable straps outboard of fairing bracket hooks to
● Fuel gauge and lamp hold wire bundles together. Cut any excess cable strap
material. See Figure 8-165.
Right side:
● Right speaker CAUTION
● Voltmeter gauge and lamp
To avoid chafing wires of interconnect harness and pos-
3. Find branch of interconnect harness terminating in sible damage to slots of outer fairing during installation,
odometer reset switch and speedometer, tachometer, verify that trim strips are installed on hooks of radio
indicator lamps, instrument nacelle switch and ambient bracket.
temperature sensor connectors. Feed connectors and
conduit from front of inner fairing through tunnel of fair- 8. Capture conduit of front turn signal lamp connectors
ing bracket and then out through opening at top of fairing [31L] and [31R], 3-place Multilocks, in flexible clips on
bracket to instrument nacelle. sides of inner fairing.

8-134 2004 Touring: Electrical

HOME

9. Install the outer fairing and windshield. See Section 2.30 11. Install bezel. See BEZEL, INSTALLATION, in this sec-
UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR- tion.
ING, INSTALLATION.
12. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
10. Install left side of instrument nacelle. See Section 2.30 MAXI-FUSE, INSTALLATION.
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, INSTALLATION, steps 5-7 and 9-10.

2004 Touring: Electrical 8-135

HOME

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
2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U), Radio Antenna
OUTER FAIRING/WINDSHIELD, REMOVAL. Cable
f1466a2x

5. Remove radio antenna cable connector [51] at back of

radio (left side). See Figure 8-166. Carefully cut cable Figure 8-167. 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
from right side of steering head. Hole Radio Antenna
Cable Connector
7. Carefully cut cable straps securing main harness to
frame backbone, left frame tube and luggage rack rail.
See Figure 8-169.
8. Open Tour-Pak and proceed as follows:
FLHTC: Remove rubber mat.

Radio Antenna
Cable [51]

Grommet
Cable
Clip f1465a2x

Figure 8-168. 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

f2238x8x separate pin and socket halves of radio antenna cable
connector. Release cable from two clips at bottom of
Figure 8-166. Remove Outer Fairing (FLHTC/U) Tour-Pak.

8-136 2004 Touring: Electrical

HOME

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 8-167.
12. Pull grommet into Tour-Pak and remove from main har- Frame
Backbone
ness conduit. 1

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

through hole at front of Tour-Pak. See Figure 8-168.
2A
14. Carefully cut radio antenna cable where it exits main
harness conduit.

3A
INSTALLATION
1. Place new radio antenna cable on motorcycle following
original routing. Note that the cable follows the branches
4A
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 5A
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
cable then runs along the right side of the frame backbone, 6 Guard
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.

2. Feed Tour-Pak lights and radio antenna cable connec- 1 Captures main harness, cruise roll-off switch conduit,
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 8-167. 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
and socket halves of radio antenna cable connector. frame tube.
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
5. Install bulb socket on left side of Tour-Pak. tube.

6. Proceed as follows:
Figure 8-169. 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 8-166. 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. 169.

2004 Touring: Electrical 8-137

HOME

11. Install the outer fairing and windshield. See Section 2.30 13. Install left side saddlebag. See Section 2.25 SADDLE-
UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIR- BAG, INSTALLATION.
ING, INSTALLATION.
14. Install fuel tank. For carbureted models, see Section 4.7
12. Align barbed studs in left side cover with grommets in FUEL TANK (CARBURETED), INSTALLATION (AFTER
frame downtubes and push firmly into place (no tools COMPLETE REMOVAL), FLHT/C. For fuel injected
required). models, see Section 9.4 FUEL TANK (FUEL
INJECTED), INSTALLATION (AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI.

8-138 2004 Touring: Electrical

HOME

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 8-171. Capture Radio Antenna Cable
radio (left side). See Figure 8-170. Carefully cut cable
where it exits branch of main harness conduit.

6. Remove screw, ground wire ring terminal and P-clamp to 9. Carefully cut cable strap to release radio antenna cable
release main harness bundle from right side of steering from shoulder of upper frame tube (just in front of air
head. valve mounting bracket). Cut cable strap to release radio
antenna cable from slotted hole in rear fender support.
7. Carefully cut cable straps securing main harness to See Figure 8-171.
frame backbone and left frame tube. See Figure 8-172. 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
Cable [51] INSTALLATION
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 8-170. Remove Outer Fairing (FLTR) cable strap to secure radio antenna cable to shoulder of

2004 Touring: Electrical 8-139

HOME

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 8-171. 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 2A
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 3A
connector [51] at back of radio (left side). See Figure 8-
170.
6. On right side of motorcycle, capture radio antenna cable
4A
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 5A
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
169.
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.
INJECTED), INSTALLATION (AFTER COMPLETE 6 Captures main harness, audio harness (FLHTCUI only),
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 8-172. Install Cable Straps

8-140 2004 Touring: Electrical

HOME

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 8-173. Disconnect pin and socket halves of Figure 8-174. 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 8-176. Carefully cut cable straps
securing audio harness to main harness, if present.
CB Antenna
Cable [50] Radio [28] 10. Release console pod connector [53], 12-place Mini-
Deutsch, from attachment clip anchored in hole at rear
of battery box. See Figure 8-174. Depress external
latches and use a rocking motion to separate pin and
socket halves.

11. 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.

12. Open Tour-Pak. Open map pocket and remove acorn

nuts. Remove map pocket and molded liner from Tour-
Pak.

13. Separate pin and socket halves of CB antenna cable

connector [50]. Release cable from clip at bottom of
Tour-Pak. See Figure 8-175.
f2238x8x 14. Pull right side grommet into Tour-Pak and remove from
CB antenna cable. Feed CB antenna cable through hole
Figure 8-173. Audio Harness Connectors at front of Tour-Pak.

2004 Touring: Electrical 8-141

HOME
a. CB antenna cable connector [50], back of radio
(right side).
Grommet
b. Audio to interconnect harness connector [6], 3-
place Deutsch (black); back of radio (right side).
Cable
Clip 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. Mate pin and socket halves of console pod connector

[53], 12-place Mini-Deutsch. Install connector onto
attachment clip anchored in hole at rear of battery box.
See Figure 8-174.

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

CB Antenna senger controls connector [41], 6-place Mini-Deutsch.
Cable Connector Feed connector back up into speaker box pressing trim
f1467b2x
ring into hole.
Figure 8-175. Disconnect CB Antenna Cable Connector
6. Pass CB antenna cable connector [50] through hole at
front of Tour-Pak. Capture cable in grommet. Install
grommet in hole with the larger OD facing inside. See
15. Moving to opposite side of motorcycle, remove trim ring Figure 8-175.
and gently pull on wire harness to draw rear left speaker/
passenger controls connector [42], 6-place Mini-Deut- 7. Mate pin and socket halves of CB antenna cable con-
sch, out of speaker box. Depress external latch and use nector. Capture antenna cable in clip at bottom of Tour-
a rocking motion to separate pin and socket halves. Pak.
16. Release rear headset receptacle from bracket at bottom 8. Moving to opposite side of motorcycle, mate pin and
of left side speaker box. Release spring from hole in socket housings of rear left speaker/passenger controls
receptacle wire jacket. connector [42], 6-place Mini-Deutsch. Feed connector
17. Remove audio harness from motorcycle. back up into speaker box pressing trim ring into hole.

9. Attach spring to rear headset receptacle using hole in

wire jacket. Capture headset receptacle in bracket at
INSTALLATION bottom of left side speaker box.

1. Place new audio harness on motorcycle following origi- 10. At front of top engine stabilizer bracket, install new 14
nal routing. Note that the audio harness follows the inch cable strap capturing frame backbone, audio har-
branches of the main harness as it is routed to the rear ness and main harness. Tighten cable strap, but leave
left and right sides of the motorcycle. loose enough so that one finger can be inserted
between strap and frame backbone. Do not over-
NOTE tighten. Cut any excess cable strap material.
Specifically, from the front of the inner fairing, the audio har- 11. Install remaining cables straps as shown in Figure 8-
ness is routed under the fairing cap where it passes through 176.
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 the outer fairing and windshield. See Section 2.29
a branch crosses to the left side at the main harness anchor UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
in the center of the frame backbone. From this point, each FAIRING/WINDSHIELD, INSTALLATION.
branch follows its respective side of the frame backbone, run-
ning along the inboard side of the upper frame tubes and 13. Align barbed studs in right side cover with grommets in
then down the luggage rack rails. frame downtubes and push firmly into place (no tools
required).
2. See Figure 8-173. Standing at front of motorcycle, mate
pin and socket halves of the following wire harness con- 14. Install right side saddlebag. See Section 2.25 SADDLE-
nectors: BAG, INSTALLATION.

8-142 2004 Touring: Electrical

HOME

15. Repeat steps 13 and 14 on left side of motorcycle.

A = Anchored
16. Install fuel tank. For carbureted models, see Section 4.7
Frame FUEL TANK (CARBURETED), INSTALLATION (AFTER
Backbone COMPLETE REMOVAL), FLHT/C. For fuel injected
1 models, see Section 9.4 FUEL TANK (FUEL
INJECTED), INSTALLATION (AFTER COMPLETE
REMOVAL), FLHT/C/U/I, FLTRI.
2A

8A 3A

9A 4A

10 A 5A

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 8-176. Install Cable Straps

2004 Touring: Electrical 8-143

HOME

CB ANTENNA CABLE (FLHTCU)

Grommet

REMOVAL
Cable
1. Remove fuel tank. For carbureted models, see Section Clip
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
(right side). Rotate knurled ring in a counterclockwise f1467b2x

direction to disconnect. See Figure 8-177. Carefully cut

cable where it exits audio harness conduit. Figure 8-178. 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 8-180. Carefully cut cable straps securing
audio harness to main harness, if present. 9. Separate pin and socket halves of CB antenna cable
connector [50]. Release cable from clip at bottom of
Tour-Pak. See Figure 8-178.

CB Antenna 10. Pull right side grommet into Tour-Pak and remove from
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 8-177. 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.

8-144 2004 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 8-178. 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.
2A
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 8-179.

5. Install molded liner in Tour-Pak. Install map pocket and 3A

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

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

4A
antenna cable connector [50] to back of radio. See Fig-
ure 8-177.

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 5A
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-

180. 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 8-180. 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 8-179. Secure CB Antenna Cable

2004 Touring: Electrical 8-145

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
right side of frame backbone, upper frame tube and Figure 8-182. Electrical Bracket (Inboard Side)
other wire harness bundles. See Figure 8-185.
7. Remove ignition coil connector [83] and manifold abso-
lute pressure sensor connector [80]. Pull external latch 8. Remove ignition control module connector [10]. Depress
outward and use rocking motion to separate pin and external latches and use a rocking motion to separate
socket halves. Draw conduit and connectors to right side pin and socket halves. See Figure 8-181.
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 8-182.

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 8-183.

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 8-181. Electrical Bracket (Under Right Side Cover)

8-146 2004 Touring: Electrical

HOME

8321

Ignition Vehicle Speed

Control Module Sensor [65B]
[10B]

Rubber
Boot

Main Harness
[8A]

Figure 8-183. 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 8-184.
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 8-183.

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 8-185.
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
halves of vehicle speed sensor connector [65]. Route Ignition
siren and vehicle speed sensor connectors and conduit Coil [83B]
on inboard side of electrical bracket as shown in Figure f2226x8x

8-182.
Figure 8-184. Ignition Wire Harness Connectors

2004 Touring: Electrical 8-147

HOME

8. Slide electrical bracket onto studs at side of battery box.

Be sure that conduit is properly routed on inboard side of A = Anchored
electrical bracket or wires may be pinched during instal-
lation. Install flange nuts and tighten to 36-48 in-lbs Frame
(4.1-5.4 Nm). Backbone

9. Install ignition control module connector [10].

10. Mate pin and socket halves of main harness connector 1A

[8]. Install connector into slot of electrical bracket. See
Figure 8-181.

11. Verify that protective plug is installed in data link connec-

tor [91]. With the plug side down and in contact with tab, 2A
position connector between arms on electrical bracket.

12. Tighten cable straps securing ignition harness to right

side of frame backbone, upper frame tube and other wire
harness bundles. Cut any excess cable strap material. 3A

13. Place battery in battery box, terminal side forward.

Rotate hold-down clamp so that lip (with rubber pad)
rests on edge of battery and tighten clamp bolt.
4A

1WARNING Saddlebag
Guard
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion producing personal injury and/or property
damage. f2225x8x

14. Insert bolt through battery positive cable (red) into

threaded hole of battery positive (+) terminal. Tighten
1 Captures ignition harness only. ANCHORED.
bolt to 60-96 in-lbs (6.8-10.9 Nm).
2 3 4 Captures main harness, audio harness (FLHTCUI only),
ignition harness and conduit to fuel tank harness (all
15. Install fuel tank. See Section 4.7 FUEL TANK (CARBU- models except FLHR/C/S). ANCHORED.
RETED), INSTALLATION (AFTER COMPLETE
REMOVAL), FLHT/C or FLHR/S.
Figure 8-185. Remove/Install Cable Straps
16. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).

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

BAG, INSTALLATION.

18. Start motorcycle and verify proper operation without set-

ting trouble codes.

8-148 2004 Touring: Electrical

HOME

EFI HARNESS (FUEL INJECTED) f2183x8x

REMOVAL
1. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,
FLTRI, or FLHR/C/S/I.
1
2. Remove air cleaner and backplate. See Section 4.5 AIR
CLEANER, REMOVAL.
3. Unthread bolt and remove battery positive cable (red)
from battery positive (+) terminal. (Battery negative
cable already removed under FUEL TANK, COMPLETE
REMOVAL.)
4. 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
5. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
6. Gently pull side cover from frame downtubes (no tools 1. Vehicle Speed Sensor [65]
required). 2. P&A Security Siren [142]

NOTE Figure 8-187. Electrical Bracket (Inboard Side)

Draw all EFI wire harness connectors to right side of motor-
cycle as they are disconnected.
7. Carefully cut five cable straps to free EFI wire harness 8. Remove idle air control connector [87] and manifold
from right side of frame backbone, upper frame tube and absolute pressure sensor connector [80]. Pull external
other wire harness bundles. See Figure 8-190. latch(es) outward and use rocking motion to separate
pin and socket halves. See Figure 8-186.

9. Depress wire form to remove front fuel injector connec-

[87A] tor [84] and rear fuel injector connector [85].
[84A] Front
10. Remove throttle position sensor connector [88] and
intake air temperature sensor connector [89].

11. Moving to left side of motorcycle, remove ignition coil

connector [83] from left side of ignition coil.

12. Pull back boot to reveal engine temperature sensor con-

nector [90] at back of front cylinder. Pull external latch
outward and remove connector. Cut cable strap to
release conduit from horn bracket.

13. Returning to right side of motorcycle, depress external

latch and remove ECM connector [78].

[85A] 14. Gently pull on data link connector [91] to disengage from
[80A] [89A] [88A] arms on electrical bracket.

15. Locate painted white dot on inboard side of fuse block

[80A] Manifold Absolute Pressure Sensor [119]. Pressing on dot, gently tug on conduit to release
[84A] Front Fuel Injector tabs on fuse block from slots in bracket.
[85A] Rear Fuel Injector
16. Pull main harness connector [8] from slot in electrical
[87A] Idle Air Control
bracket. Depress external latches and use a rocking
[88A] Throttle Position Sensor
motion to separate pin and socket halves.
[89A] Intake Air Temperature Sensor f2162x9x
17. Remove two flange nuts to release electrical bracket
Figure 8-186. Induction Module Assembly (Top View) from studs on side of battery box.

2004 Touring: Electrical 8-149

HOME

INSTALLATION
8321
1. Standing on right side of vehicle, carefully feed sensor
connectors and conduit through opening into battery
box. See lower frame of Figure 8-188. Pull up on har-
ness and tuck conduit into space in front of the battery
box TORX screw.

CAUTION

Rubber Damage to wires can result in electrical problems. Be

Boot sure that rubber boot is present on threaded end of bat-
tery box TORX screw. Replace rubber boot if absent or
damaged. See upper frame of Figure 8-183.

2. Draw sensor connectors and conduit up along right side

of frame backbone just below the main wire harness
bundle.
3. Loosely install five new cable straps to secure EFI wire
harness to right side of frame backbone, upper frame
tube and other wire harness bundles. See Figure 8-190.
4. Install front fuel injector connector [84] and rear fuel
injector connector [85]. See Figure 8-186.
5. Install manifold absolute pressure sensor connector [80]
and idle air control connector [87].
6. Install intake air temperature sensor connector [89] and
throttle position sensor connector [88].
7. Feed ignition coil and engine temperature sensor con-
nectors to left side of vehicle, routing the first in front of
the top engine stabilizer link, the latter to the rear.

8319 8. Install ignition coil connector [83] onto left side of ignition
coil.
Figure 8-188. Remove EFI Harness From Vehicle 9. Install engine temperature sensor connector [90] at back
of front cylinder. Pull boot over sensor to keep out dirt
and debris. Install new cable strap to secure connector
18. On inboard side of electrical bracket, disconnect vehicle conduit to horn bracket.
speed sensor connector [65]. Depress button on socket 10. Mate pin and socket halves of vehicle speed sensor con-
housing and pull apart pin and socket halves. See Fig- nector [65].
ure 8-187.
11. Install security siren connector [142] and vehicle speed
sensor connector [65] on inboard side of electrical
CAUTION bracket as shown in Figure 8-187. Be sure that conduit
and cables are properly routed or wires may be pinched
Damage to wires can result in electrical problems. Be during installation.
sure that rubber boot is present on threaded end of bat-
tery box TORX screw. Replace rubber boot if absent or 12. Slide electrical bracket onto studs at side of battery box.
damaged. See upper frame of Figure 8-188. Install flange nuts and tighten to 36-48 in-lbs (4.1-5.4
Nm).
19. Note that harness conduit runs forward of the front bat- 13. Mate pin and socket halves of main harness connector
tery box TORX screw. Pull conduit to the rear of the [8]. Install connector into slot of electrical bracket.
screw, and then draw sensor connectors and conduit
down right side of frame backbone into battery box. 14. Engage tabs on fuse block [119] with slots in electrical
bracket. Slide fuse block up into cavity. Gently tug on
20. Pull connectors and conduit out through opening at side conduit to verify that fuse block is locked in place.
of battery box to remove harness from vehicle. See 15. Install ECM connector [78]. Push connector halves
lower frame of Figure 8-188. together until latch clicks.

8-150 2004 Touring: Electrical

HOME

[78B]

[65B]

[8A]

ECM Power [91A]

Fuse
Fuel Pump
Fuse

Spare
Fuse [119B]

EFI System
Relay
[88B]

[90B]
[89B]

[80B]

Rubber
Boot

[85B]

[84B]

[87B]
[8A] Main Harness
[65B] Vehicle Speed Sensor
[78B] Electronic Control Module (ECM)
[80B] Manifold Absolute Pressure Sensor [88B] Throttle Position Sensor
[83B] Ignition Coil [89B] Intake Air Temperature Sensor
[84B] Front Injector [90B] Engine Temperature Sensor [83B]
[85B] Rear Injector [91A] Data Link
[87B] Idle Air Control [119B] EFI Fuse Block f2224x9x

Figure 8-189. EFI Wire Harness Connectors

2004 Touring: Electrical 8-151

HOME

16. Verify that protective plug is installed in data link connec-

tor [91]. With the plug side down and in contact with tab, A = Anchored
position connector between arms on electrical bracket.
17. Tighten five cable straps securing EFI wire harness to Frame
Backbone
right side of frame backbone, upper frame tube and
other wire harness bundles. Cut any excess cable strap
material.
1A
18. Place battery in battery box, terminal side forward.
Rotate hold-down clamp so that lip (with rubber pad)
rests on edge of battery and tighten clamp bolt.

1WARNING 2A

Always connect the positive battery cable first. If the

positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
3A
explosion producing personal injury and/or property
damage.

19. Insert bolt through battery positive cable (red) into

threaded hole of battery positive (+) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm). 4A
Saddlebag
20. See Section 9.4 FUEL TANK (FUEL INJECTED), Guard
INSTALLATION (AFTER COMPLETE REMOVAL),
FLHT/C/U/I, FLTRI, or FLHR/C/S/I
21. Install backplate and air cleaner. See Section 4.5 AIR
CLEANER, INSTALLATION.
f2225x8x
22. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required). 1 Captures EFI harness only (front injector, idle air control
and ignition coil conduit). ANCHORED.
23. Install right side saddlebag. See Section 2.25 SADDLE-
2 3 4 Captures main harness, audio harness (FLHTCUI only),
BAG, INSTALLATION. EFI harness and conduit to fuel tank harness (all models
except FLHR/C/S). ANCHORED.
24. Start vehicle and verify proper operation without setting
trouble codes.
Figure 8-190. Remove/Install Cable Straps

8-152 2004 Touring: Electrical