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IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.18

1WARNING
Knob
DO NOT modify the ignition/light key switch wiring to
disable the automatic-on headlamp feature. High visibil-
ity is an important safety consideration for motorcycle
riders. Ensure that the headlamp is on at all times. Fail-
ure to do so could result in death or serious injury.

FLHT/C/U, FLTR (DOMESTIC)

Nut

REMOVAL
Collar Tab
1. Remove the outer fairing. See Section 2.29 UPPER
Down and Forward
FAIRING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
WINDSHIELD, REMOVAL.
2. To remove the ignition switch knob, insert the Ignition
Switch key and turn to the UNLOCK position. Leaving Spacer Socket
the key installed, rotate the knob to ACCESS. Depress- Screw
ing the release button at bottom (left side) with a small
screwdriver, push key down and turn an additional 60
degrees in a counter-clockwise direction. Lift and Flat
remove knob. See Figure 8-61. Washer

f1240x2x

Switch
Housing

4-Place
Button
TOP VIEW Packard
Connector
f2115x8x

Figure 8-62. Ignition Switch Assembly (Domestic)

3. Using a 7/8 inch wrench on flats, loosen switch nut and

remove from threaded post of ignition switch housing.
Button Remove collar and spacer. See Figure 8-62.
4. Using a T27 TORX drive head, remove the two screws
(with flat washers) that secure fairing cap to left and right
sides of inner fairing.
5. Remove the switch position plate by pulling tabs from
f1476x8x BOTTOM VIEW
slots in fairing cap. If necessary, raise the fairing cap
slightly to facilitate removal.
Figure 8-61. Ignition Switch Knob Release Button

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6. With the forks turned fully to the left, disconnect the Fair-
ing cap switch connector [105], 12-place Multilock Ignition Switch
(black), from behind right side of fairing cap. Depress the Connector [33]
button on the plug side of the connector to pull apart the
pin and socket halves.

7. Remove the fairing cap from the motorcycle. See Figure

8-63.

8. Locate the Ignition switch connector [33], 4-place Pack-

ard, at bottom of radio. Slide connector off anchor and
separate pin and socket halves. See Figure 8-64.

9. Remove the socket screws (with flat washers) and lift the
switch housing from the upper fork bracket bore. Route
the Ignition switch connector to rear of inner fairing and
remove switch housing from the vehicle.

INSTALLATION
1. Slide base of ignition switch into bore of upper fork f2238x8x
bracket. Install screws (with flat washers) and tighten to
36-60 in-lbs (4.1-6.8 Nm). Figure 8-64. Ignition Switch Connector Location
2. Route the Ignition switch connector [33], 4-place Pack- (FLHT/C/U)
ard, to front of inner fairing. Mate pin and socket halves
of connector and install onto anchor at bottom of radio.
See Figure 8-64. 6. Install switch position plate fitting tabs in slots of fairing
3. Verify that the rubber grommets are installed on each cap. Plate snaps in place when properly installed. Exer-
side of the fairing cap. Barbs on cap fit into holes in cise care to avoid breaking tabs. Replace plate if tabs
grommets. are broken.

4. Connect the Fairing cap switch connector [105], 12- 7. Using a T27 TORX drive head, start two fairing cap
place Multilock (black), on the right side of fairing cap. screws (with flat washers). Verify that grommets in fair-
ing cap fully capture handlebar along with throttle and
5. With the forks turned fully to the left, install fairing cap clutch cables.
over ignition switch housing.
8. Slide spacer over threaded post of ignition switch hous-
ing until it contacts switch position plate. Slide collar over
post with the tab side down (and forward). Install nut,
f1305b2x
and using a 7/8 inch wrench on flats, tighten to 50-70 in-
lbs (5.7-7.9 Nm).

9. With the red arrow pointing toward the ACCESS posi-

tion, install the ignition switch knob. Turn key clockwise
to UNLOCK position and then turn knob to OFF.

10. Using a T27 TORX drive head, tighten two fairing cap
screws to 25-30 in-lbs (2.8-3.4 Nm).

11. Verify operation of both the ignition switch and fork lock
assemblies.

12. Install the outer fairing. See Section 2.29 UPPER FAIR-
ING/WINDSHIELD (FLHT/C/U), OUTER FAIRING/
Fairing Cap
Switch Connector [105] WINDSHIELD, INSTALLATION.
12-Place Multilock

Figure 8-63. Fairing Cap Assembly (FLHT/C/U)

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FLHT/C/U, FLTR
(INTERNATIONAL)

REMOVAL
1. Remove the ignition switch knob as follows:

a. Insert the ignition switch key and turn to the

UNLOCK position. Leave the key installed in the
ignition switch knob.
b. Turn the front forks to the left fork stop and rotate
Figure 8-66. Ignition Switch Alignment Tool
the knob to FORK LOCK.
(Part No. HD-45962)
c. Depressing the release button at bottom (left side)
with a small screwdriver, push key down and turn 60
degrees in a counter-clockwise direction. See Fig-
ure 8-65.
d. Lift and remove knob. Be aware that spring will drop
out of bore at underside of knob when removed.

f2080x8x

f2086x8x

Figure 8-67. Bottom Alignment Tool in Threaded Post

and Rotate to Desired Position

NOTE
Button
TOP VIEW After removal of the knob, the IGNITION SWITCH ALIGN-
MENT TOOL (HD-45962) may be used to move the switch to
other positions as required. Insert tool until bottom of handle
contacts top of threaded post, and then rotate handle in a
clockwise direction to the selected position. See Figure 8-67.

2. Turn the front forks to the right fork stop, and using a 7/8
Button inch open end wrench on flats, remove nut from
threaded post of ignition switch housing.

3. Pull collar and spacer from threaded post.

4. Remove the switch position plate by pulling tabs from

slots in fairing cap (FLHT/C/U) or instrument nacelle
(FLTR).

5. FLTR: Remove the instrument nacelle. See Section 2.30

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, REMOVAL.

f2097x8x
BOTTOM VIEW FLHT/C/U: Remove the fairing cap. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
Figure 8-65. Ignition Switch Knob Release Button CAP, REMOVAL.

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8. Disconnect the ignition switch jumper harness connector
[33], 3-place Packard, at front of ignition switch housing.
Proceed as follows:

a. Obtain the IGNITION SWITCH CONNECTOR

REMOVER (HD-45961). See Figure 8-68.
b. Gently insert end of tool into slot in ignition switch
housing until it stops.
c. Grasping jumper harness conduit and tool, pull both
at the same time to release socket housing from
ignition switch housing. See Figure 8-69.
Figure 8-68. Ignition Switch Connector Remover NOTE
(Part No. HD-45961)
For instructions on properly removing and installing jumper
harness terminals, see APPENDIX B.4 AUTOFUSE ELEC-
TRICAL CONNECTOR.
f2090x8x

INSTALLATION
1. Install Ignition switch jumper harness connector [33], 3-
place Packard, at front of new ignition switch housing.
2. Slide base of ignition switch housing into bore of upper
fork bracket.

CAUTION

Verify that the threads in the upper fork bracket are clean
and in good condition. Dirty and/or damaged threads
may cause the heads of the break-away screws to snap
off before the switch housing is properly tightened.
Figure 8-69. Pull Jumper Harness Conduit and Tool
to Release Socket Housing
CAUTION

Exercise care to avoid losing heads of break-away

1WARNING screws in vehicle. Vibration may cause captured heads
to scratch finished surfaces, chafe wires or cause other
Always wear proper eye protection when drilling. Flying damage.
debris may result in eye injury.
3. Install new break-away screws at base of ignition switch
housing. Turn screws in a clockwise direction until heads
6. Remove the two break-away screws at the base of the
snap off.
ignition switch housing. Proceed as follows:
4. FLTR: Install the instrument nacelle. See Section 2.30
a. Use a center punch to make a pilot hole at the top of UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
each break-away screw. NACELLE, INSTALLATION.

b. Install a 1/8 inch left handed bit in drill and set the FLHT/C/U: Install the fairing cap. See Section 2.29
drill to Reverse. Positioning the bit in the pilot hole, UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
spin out the break-away screws. CAP, INSTALLATION.

5. Install switch position plate fitting tabs in slots of fairing

NOTE
cap (FLHT/C/U) or instrument nacelle (FLTR). Plate
If the above method fails, use a 3/16 inch bit with long shank snaps in place when properly installed. Exercise care to
to carefully drill off heads of break-away screws. Use a pliers avoid breaking tabs. Replace plate if tabs are broken.
to unthread the shafts from the upper fork bracket. 6. Install spacer over threaded post of ignition switch hous-
ing until it contacts switch position plate. Orient spacer
7. Remove ignition switch housing from upper fork bracket so that the widest side is forward and the inside tabs fit
bore. in slots of post. See Figure 8-70.

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12. Knob was removed in ACCESS or switch may have
1. Knob been moved out of the FORK LOCK position. Proceed
2. Spring
1 as follows:
3. Nut
4. Collar a. Insert alignment tool until bottom of handle contacts
5. Spacer top of threaded post, and holding front forks at the
6. Break-Away Screw left fork stop, rotate handle of tool in a counter-
7. Flat Washer clockwise direction until fork locks. See Figure 8-67.
8. Switch Housing b. Remove tool and repeat step 10.

c. If knob does not install properly, move to step 13.

2 13. Detent and switch position lugs are misaligned. This can
occur when the alignment tool (or ignition switch knob) is
3 rotated before it is properly bottomed in the ignition
switch housing. Proceed as follows:

a. Reinstall knob inserting shaft into threaded post and

4 gently rotate knob until it drops into the partially
installed position. Take note of the position of the
knob, that is, whether it is pointing toward the rear,
5 or to ACCESS, IGNITION or OFF.
6 b. Remove knob and insert alignment tool so that the
bottom of the handle is approximately 1/2-3/4 inch
(12.7-19.1 mm) from the top of the threaded post,
and then hold. See Figure 8-71.
7
c. Rotate alignment tool in a counter-clockwise
direction the number of positions needed to get to
8 f2116x8x FORK LOCK. For example, if the knob dropped into
the partially installed position at IGNITION in step
Figure 8-70. Ignition Switch Assembly (International) 13(a), rotate the alignment tool two positions in a
counter-clockwise direction. Or if the knob was
pointing toward the rear when it dropped, rotate the
7. Slide collar over threaded post until it contacts spacer. alignment tool four positions in a counter-clockwise
Orient collar so that the outside tab is forward and the direction or one position in a clockwise direction.
inside tabs fit in slots of post. Repeat step 10.
8. Thread nut onto post with the lipped side down and the
smaller OD topside. Turn the front forks to the right fork
stop, and using a 7/8 inch Open End Crow Foot on flats,
tighten nut to 125-150 in-lbs (14.1-16.9 Nm).
9. Install spring into bore at underside of knob.
10. With the knob pointing toward the FORK LOCK position,
insert shaft into threaded post. Holding the knob down,
turn key clockwise to UNLOCK. An audible “click” should
be heard when knob and switch are properly engaged.
Release knob and then rotate through all four switch
positions to verify proper operation.
If knob will not install properly, move to step 11.
11. Proceed as follows:
a. Verify that button at bottom of knob is depressed
f2087x8x
and key is turned 60 degrees beyond the UNLOCK
position. See Figure 8-65.
b. Repeat step 10. Figure 8-71. Rotate Alignment Tool Without Bottoming

c. If knob does not install properly, move to step 12.

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6. Raise instrument console and bend back flexible clamp
Ignition/Light on canopy to release main harness conduit. Depress
Key Switch Connector [33] button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
7. Lay a clean shop towel on forward part of rear fender.
Lift the instrument console from fuel tank and lay upside
down on shop towel.
8. Pull external latches outward to disconnect ignition/light
key switch connector [33], 3-place Packard. See Figure
8-72.
9. Remove four screws to release switch from console.

Installation
1. Align holes in new switch with those in console. See Fig-
ure 8-72.
2. Start four screws and alternately tighten to 20-30 in-lbs
(2.3-3.4 Nm) in a crosswise pattern.
3. Connect ignition/light key switch connector [33], 3-place
Packard.
Screw f2095x8x
4. Slide head of console mounting bolt into slot at top of
canopy.
Figure 8-72. Instrument Console (FLHR/C)
5. Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3-
place Mini-Deutsch, at top of canopy. Bend flexible
FLHR/C/S clamp to capture main harness conduit.
6. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
IGNITION/LIGHT KEY SWITCH 7. Install acorn nut at top of instrument console and tighten
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Removal Phillips screw and large flat washer (absent on FLHRS
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
1. Remove seat. See Section 2.24 SEAT, REMOVAL. 8. On FLHRS models only, install bolt (with flat washer) to
secure rear of fuel tank and instrument console bracket
1WARNING to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
Nm).
To protect against shock and accidental start-up of vehi- 9. Snap anchor of new cable strap into hole on left side of
cle, disconnect the negative battery cable before pro- frame backbone. Tighten cable strap capturing main har-
ceeding. Inadequate safety precautions could result in ness bundle, instrument console conduit, and fuel vapor
death or serious injury. vent tube. Cut any excess cable strap material.

2. Unthread bolt and remove battery negative cable (black) 10. Insert bolt through battery negative cable (black) into
from battery negative (-) terminal. threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
3. Carefully cut anchored cable strap securing main har- 11. Install seat. See Section 2.24 SEAT, INSTALLATION.
ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.

4. Remove acorn nut from instrument console. If present, FORK LOCK

also remove Phillips screw and large flat washer (absent
on FLHRS models). Removal
1. Remove the handlebar clamp shroud. See Section 2.31
5. On FLHRS models only, remove bolt (with flat washer) to WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S),
free rear of fuel tank from frame backbone. Removal of NACELLE REMOVAL (FLHR/C), steps 1-11, or
rear bolt also releases instrument console bracket. NACELLE REMOVAL (FLHRS), steps 1-7.

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3. Install the handlebar clamp shroud. See Section 2.31
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S),
f2101x8x
NACELLE INSTALLATION (FLHR/C), steps 3-15, or
NACELLE INSTALLATION (FLHRS), steps 5-13.

Figure 8-73. Fork Lock (FLHR/C/S)

2. Start acorn nuts on both the left and right side fork studs
to keep halves of headlamp nacelle on motorcycle.
3. Remove two allen head socket screws (with flat wash-
ers) and pull fork lock assembly from upper fork bracket
bore. See Figure 8-73.

NOTE
On HDI models, use a center punch to make a pilot hole at
the top of each break-away screw. Install a 1/8 inch left
handed bit in drill and set the drill to reverse. Positioning the
bit in the pilot hole, spin out the break-away screws.

Installation
1. Install new fork lock assembly into bore of upper fork
bracket. See Figure 8-73.
2. Install two allen head socket screws (with flat washers)
and alternately tighten to 36-60 in-lbs (4.1-6.8 Nm).

NOTE
On HDI models, install new break-away screws and turn in a
clockwise direction until heads snap off. Verify that threads in
upper fork bracket are clean and in good condition or heads
may break off before fork lock assembly is properly tightened.
Avoid losing heads of screws in vehicle as vibration may
cause captured heads to scratch finished surfaces, chafe
wires or cause other damage.

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FAIRING CAP SWITCHES (FLHTC/U) 8.19

REMOVAL
f1240x2x

1. Partially disassemble domestic ignition switch as follows:

NOTE
For partial disassembly of HDI ignition switch, see Section
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
a. See Figure 8-74. To remove the ignition switch
knob, insert the Ignition Switch key and turn to the
UNLOCK position. Leaving the key installed, rotate Button
the knob to ACCESS. Depressing the release but- TOP VIEW
ton at bottom (left side) with a small screwdriver,
push key down and turn an additional 60 degrees in
a counter-clockwise direction. Lift and remove knob. BOTTOM VIEW
b. Using a 7/8 inch wrench on flats, loosen switch nut
and remove from threaded post of ignition switch
housing. Remove collar and spacer.
Button
c. Gently remove the switch position plate by pulling
tabs from slots in fairing cap. If necessary, raise the
fairing cap slightly to facilitate removal.
2. Using a T27 TORX drive head, remove the two screws f1476x8x
(with flat washers) that secure fairing cap to left and right
sides of inner fairing. Figure 8-74. Ignition Switch Knob Release Button
3. With the forks turned fully to the left, disconnect the fair-
ing cap switch connector [105], 12-place Multilock
(black), from behind right side of fairing cap. Depress the 10. Remove the appropriate terminals from the socket hous-
button on the socket terminal side of the connector and ing.
pull apart the pin and socket halves.
4. Remove the fairing cap from the motorcycle. See Figure NOTE
8-75. For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
5. Bend back the flexible clamp to release switch wires TORS, REMOVING SOCKET/PIN TERMINALS.
from the inboard side of the fairing cap. Carefully cut
cable straps to free wires from bundles.
6. Using a T25 TORX drive head, remove two screws to
release switch bracket. INSTALLATION
7. Gently pry two latches on bracket outward to release
tabs on switch. Remove switch from bracket. See Figure 1. Feeding wires through bracket, place new switch into
8-76. position. Engage tabs on switch in slots of latches and
then gently bend tabs upward to lock position of switch
8. If replacing Cruise or Speaker Switch, cut Black/Green
in bracket.
wire lead halfway between Cruise and Speaker Switch
terminals. 2. Install terminals into socket housing.
9. Follow the wires of the faulty switch to the socket hous-
NOTE
ing, or reference Figure 8-77 and Table 8-10 for the
applicable chamber numbers. For wire location pur- For instructions on properly installing wire terminals, see
poses, numbers are stamped into the secondary locks of APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
both the pin and socket housings. TORS, INSTALLING SOCKET/PIN TERMINALS.

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Accessory Switch f1305b2x

Switch Cruise Bracket
Grommet Switch

Speaker
Switch
Spotlight
Switch

Cable
Strap
Grommet

Flexible
Clamp

Socket Housing Cable

12-place Multilock Strap Switch Bracket
Fairing Cap Switch Connector [105] TORX Screws

Figure 8-75. Fairing Cap (Inboard Side) - Ultra Model Shown

3. If Cruise or Speaker Switch was replaced, butt splice

Black/Green wire lead between Cruise and Speaker Latch
Switch terminals.

NOTE Tab
For detailed butt splicing information, see APPENDIX B.5
SEALED BUTT SPLICE CONNECTORS.

4. Using a T25 TORX drive head, install two screws to

secure switch bracket to fairing cap.
5. Install new cable straps to capture wire bundles and
then secure switch wires to the fairing cap using the flex- Switch
ible clamp. Route the wires as shown in Figure 8-75. Bracket
6. Verify that the rubber grommets are installed on each
side of the fairing cap. Barbs on cap fit into holes in
grommets.
7. Connect the fairing cap switch connector [105], 12-place
Multilock (black), on the right side of fairing cap. Cable
Strap
8. With the forks turned fully to the left, install fairing cap
over ignition switch housing. Verify that grommets in fair-
ing cap fully capture handlebar along with throttle and
clutch cables.
9. Start two fairing cap screws (with flat washers). Using a f1304b2x

T27 TORX drive head, alternately tighten screws to 25-

30 in-lbs (2.8-3.4 Nm). Figure 8-76. Bend Latches Outward to Release Tabs

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10. Assemble domestic ignition switch as follows:

NOTE
1 2 3 4 5

For assembly of HDI ignition switch, see Section 8.18 IGNI-

TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U,
FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.

a. Install switch position plate fitting tabs in slots of fair-

ing cap. Plate snaps in place when properly
– AMP
installed. Exercise care to avoid breaking tabs.
6 7 8 9 10 11 12 Replace plate if tabs are broken.

b. Slide spacer over threaded post of ignition switch

Secondary Locks Open f1287b2x housing until it contacts switch position plate.

Figure 8-77. Numbers Stamped on Secondary Locks c. Slide collar over post with the tab side down (and
(Socket Housing Shown) forward).

d. Install nut, and using a 7/8 inch wrench on flats,

Table 8-10. Fairing Cap Switches [105] tighten to 50-70 in-lbs (5.7-7.9 Nm).

Chamber e. With the red arrow pointing toward the ACCESS

Switch Wire Color position, install the ignition switch knob. Turn key
Number
clockwise to UNLOCK position and then turn knob
Orange/Red 1 to OFF.
Accessory Orange 2
Black 3
Orange/Violet 4
Cruise Red/Green 5
Ultra Only
Black/Green To
(Double Lugged) 12 Speaker
Switch

Yellow 6
Spot Gray/Black 7
Black 8
Orange/Blue 9

Speaker Violet/Orange 10
Ultra Only Brown/Orange 11
Black/Green To Cruise Switch

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INSTRUMENT NACELLE SWITCHES (FLTR) 8.20

REMOVAL NOTE
For partial disassembly of HDI ignition switch, see Section
8.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK,
1. Using a T25 TORX drive head, remove screw on left and FLHT/C/U, FLTR (INTERNATIONAL), REMOVAL, steps 1-4.
right side of instrument bezel.
a. To remove the ignition switch knob, insert the Igni-
2. Use thumbs to push tab at rear of bezel from slot in front tion Switch key and turn to the UNLOCK position.
of ignition switch. Gently raise free side of bezel until Leaving the key installed, rotate the knob to
tabs at front of instrument nacelle become disengaged ACCESS. Depressing the release button at bottom
from slot at front of bezel (concealed behind decorative (left side) with a small screwdriver, push key down
adhesive strip). and turn an additional 60 degrees in a counter-
clockwise direction. Lift and remove knob. See
3. Raising bezel slightly, remove anchor on ambient tem- upper frame of Figure 8-79.
perature sensor from hole in bottom inboard ear of
b. Using a 7/8 inch wrench on flats, loosen switch nut
speedometer bracket.
and remove from threaded post of ignition switch
housing. Remove collar and spacer. See lower
4. See Figure 8-78. Disconnect instruments and indicator
frame of Figure 8-79.
lamps from interconnect harness as follows:
c. Remove the switch position plate from threaded
● Speedometer connector [39], 12-place Packard. post of ignition switch housing.
● Tachometer connector [108], 12-place Packard. 7. Follow instructions based on location of defective switch.
● Indicator lamps connector [21], 10-place Multilock.

LEFT SIDE SWITCH

5. Remove bezel from motorcycle.
a. See Figure 8-78. Disconnect left side switch from
6. Partially disassemble domestic ignition switch as follows: instrument nacelle switch harness as follows:

Indicator Instrument Nacelle

f2219x8x Switches [105]
Lamps [21]

Tachometer
Gauge [108]
Speedometer
Gauge [39]
Throttle
Cables
Clutch
Cable

Speaker Ambient
Switch [105] Temperature
Sensor [107]

Figure 8-78. Instrument Nacelle (Bezel Removed)

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RIGHT SIDE SWITCHES

TOP VIEW BOTTOM VIEW
a. See Figure 8-78. Disconnect left side switch from
instrument nacelle switch harness as follows:
● Speaker Switch connector [105], 4-place Multilock.
b. See Figure 8-78. Disconnect instrument nacelle
switches from interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
Button c. Pull throttle cable clip from hole on right side of
Button instrument nacelle.
f1240x2x f1476x8x
d. Using a T40 TORX drive head, remove two bolts
(with flat washers) to release right side of instru-
f1297b2x
ment nacelle from fork side. Move right side of
nacelle to bench area leaving left side on motorcy-
cle. See Figure 8-82.
e. Gently bend back molded retainer to release switch
bracket assembly from instrument nacelle.
Knob
f. Carefully pry two latches on bracket outward to
release tabs on switch. Remove switch from
Nut bracket. See Figure 8-80.
g. Remove the appropriate terminals from the socket
and pin housings. Follow the wires of the faulty
Tab Collar switch or reference Table 8-11 for the applicable
Down and Forward chamber numbers. For wire location purposes,
numbers are stamped into the secondary locks. See
Figure 8-81.

Spacer

Figure 8-79. Ignition Switch Knob (Domestic) Latch

Tab

● Speaker Switch connector [105], 4-place Multilock.

b. Pull clutch cable clip from hole on left side of instru-

ment nacelle.

c. Using a T40 TORX drive head, remove two bolts Switch

(with flat washers) to release left side of instrument Bracket
nacelle from fork side.

d. Unthread rubber boot from odometer reset switch,

and while carefully removing left side instrument
nacelle from motorcycle, pull odometer reset switch
from hole. Move left side of nacelle to bench area
leaving right side on motorcycle. See Figure 8-82.

e. Gently bend back molded retainer to release switch

bracket assembly from instrument nacelle.

f. Carefully pry two latches on bracket outward to f2215x8x

release tabs on switch. Remove switch from
bracket. See Figure 8-80. Figure 8-80. Bend Latches Outward to Release Tabs

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Table 8-11. Right Side b. Snap switch bracket into molded retainer in instru-
ment nacelle.
Instrument Nacelle Switches
c. While carefully placing left side of instrument
Chamber Number nacelle on motorcycle, slide odometer reset switch
through hole and install rubber boot.
Switch Wire Color 12-Place 4-Place
Multilock Multilock d. See Figure 8-78. Connect left side switch to instru-
Socket Pin ment nacelle switch harness as follows:

Orange/Red 1 ● Speaker Switch connector [105], 4-place Multilock.

Accessory Orange 2 e. Using a T40 TORX drive head, install two bolts (with
flat washers) to fasten left side instrument nacelle to
Black 3 fork side. Alternately tighten bolts to 15-20 ft-lbs
(20-27 Nm).
Orange/Violet 4
f. Capture clutch cable in cable clip. Insert cable clip
Red/Green 5 into hole in left side of instrument nacelle.
Cruise
Black/Green g. Move to RIGHT SIDE SWITCHES, step 2.
12 4
(Double Lugged)

RIGHT SIDE SWITCHES

1 2 3 4 5
a. Place new switch into position in bracket. Engaging
tabs on switch in slots of latches, gently bend tabs
upward to lock position of switch in bracket. See
Figure 8-80.
b. Push terminals through two lengths of conduit to
wire end of socket or pin housing. For best results,
push one wire through conduit at a time.
– AMP c. Install terminals into socket or pin housing. See
6 7 8 9 10 11 12 Table 8-12 and Figure 8-81.

Secondary Locks Open f1287b2x

NOTE
For instructions on properly installing wire terminals, see
Figure 8-81. Numbers Stamped on Secondary Locks APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
(Socket Housing Shown) TORS, INSTALLING SOCKET/PIN TERMINALS.

d. Snap switch bracket into molded retainer in instru-

ment nacelle.
NOTE
e. Install right side of instrument nacelle on motorcy-
For instructions on properly removing wire terminals, see cle.
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS. f. See Figure 8-78. Connect left side switch to instru-
ment nacelle switch harness as follows:
h. Carefully pull wires to draw terminals through con-
● Speaker Switch connector [105], 4-place Multilock.
duit to backside of switch. For best results, pull one
wire at a time. g. See Figure 8-78. Connect instrument nacelle
switches to interconnect harness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
INSTALLATION
h. Using a T40 TORX drive head, install two bolts (with
1. Follow instructions based on location of defective switch. flat washers) to fasten right side instrument nacelle
to fork side. Tighten bolts to 15-20 ft-lbs (20-27 Nm).
LEFT SIDE SWITCH i. Capture throttle cables in cable clip. Insert cable clip
a. Place new switch into position in bracket. Engaging into hole in right side of instrument nacelle.
tabs on switch in slots of latches, gently bend tabs
upward to lock position of switch in bracket. 2. Assemble domestic ignition switch as follows:

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f2214x8x CONNECTOR DESCRIPTION

NUMBER [A, C] = Pin [B, D] = Socket
LEFT SIDE
[105A, 105B] Interconnect to Nacelle Switch Harness
[105]
[105C, 105D] Nacelle Switch Harness to Speaker Switch

Throttle
Cable Clip

RIGHT SIDE

Speaker
Switch [105D]
4-Place Multilock

Clutch
Cable Clip

Instrument Nacelle
Switches [105B]
12-Place Multilock

Speaker
Switch [105C]
4-Place Multilock
f2213x8x

Figure 8-82. Instrument Nacelle Halves

NOTE c. With the red arrow pointing toward the ACCESS

position, install the ignition switch knob. Turn key
For assembly of HDI ignition switch, see Section 8.18 IGNI- clockwise to UNLOCK position and then turn knob
TION/LIGHT KEY SWITCH AND FORK LOCK, FLHT/C/U, to OFF.
FLTR (INTERNATIONAL), INSTALLATION, steps 5-10.
3. See Figure 8-78. Looking into the instrument nacelle,
a. Install the switch position plate over threaded post connect instruments and indicator lamps to interconnect
of ignition switch housing. Tabs on plate fit in holes harness as follows:
at top of instrument nacelle.
● Speedometer connector [39], 12-place Packard.
b. Slide spacer over threaded post of ignition switch
● Tachometer connector [108], 12-place Packard.
housing until it contacts switch position plate. Slide
collar over post with the tab side down (and for- ● Indicator lamps connector [21], 10-place Multilock.
ward). Install nut, and using a 7/8 inch wrench on
flats, tighten to 50-70 in-lbs (5.7-7.9 Nm). See 4. Install anchor on ambient temperature sensor into hole
lower frame of Figure 8-79. in bottom inboard ear of speedometer bracket.

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5. Verify that left and right sides of instrument nacelle are NOTE
properly mated. Pins on left side of nacelle must fully
engage holes on right. If tabs do not properly engage slot at front of bezel, then a
loose fit will result. Remove decorative adhesive strip by gen-
6. Insert tab at rear of bezel into slot of instrument nacelle tly prying up outer edges, and using a flat bladed screwdriver,
(just in front of ignition switch). Holding left and right carefully raise tabs so that they engage lip in slot. If dam-
sides of nacelle together, place bezel over instrument aged, install new decorative adhesive strip.
nacelle flange. When properly mated, tabs at front of
instrument nacelle engage lip in slot at front of bezel 7. Using a T25 TORX drive head, install screw on each
(behind decorative adhesive strip). side of bezel. Tighten screws to 25-35 in-lbs (2.8-4.0
Nm).

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HANDLEBAR SWITCHES 8.21

GENERAL NOTE
Use the eyelet of an ordinary cable strap if the cardboard
insert is not available.
The basic switch configuration is the “Road King.” The Road
King switches have no specialized functions. Other switches, 1. Place the cardboard insert between the brake lever and
referred to as the Road King Classic, Classic and Ultra, have lever bracket. See Figure 8-83.
additional functions, such as cruise control, sound system
2. Using a T27 TORX drive head, remove the two screws
controls, etc., which cause them to differ from the Road King
with flat washers securing the handlebar clamp to the
switches. To accommodate these added functions, special
master cylinder housing. Remove the brake lever/master
lower switch housings are provided.
cylinder assembly and clamp from the handlebar.
NOTE 3. Using a T25 TORX drive head, remove the upper and
Regardless of model or option, all vehicles use the same lower switch housing screws.
upper switch housings. The vehicles and their switch configu-
4. Remove the friction shoe from the end of the tension
rations are as follows:
adjuster screw (non cruise equipped models only).
Table 8-12. Handlebar Switches NOTE
The friction shoe is a loose fit and may fall out or become dis-
Road King lodged if the lower switch housing is turned upside down or
FLHR FLHRI FLHRS FLHRSI shaken.

Road King Classic 5. Remove the brass ferrules from the notches on the
inboard side of the throttle control grip. Remove the fer-
FLHRCI rules from the cable end fittings.
Classic 6. Remove the throttle control grip from the end of the han-
dlebar.
FLHT FLHTI FLHTC FLHTCI
7. Pull the crimped inserts at the end of the throttle and idle
Ultra control cable housings from the lower switch housing.
FLTRI FLHTCUI For best results, use a rocking motion while pulling.
Place a drop of light oil on the retaining rings, if neces-
NOTE: See Figures 8-91 thru 8-94 for illustrations. sary. Remove the cables from the switch housing.
8. Cut two cable straps to release wire harness conduit
NOTE from handlebar.
To replace or repair individual switches in either the right or
left handlebar switch assemblies, see SWITCH REPAIR/
REPLACEMENT in this section.
7959

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

RIGHT HANDLEBAR CONTROLS

CAUTION 5/32 Inch

(4.0 mm)
Do not remove the switch housing assembly without first Cardboard
placing the 5/32 inch (4.0 mm) cardboard insert between Insert
the brake lever and lever bracket. Removal without the
insert may result in damage to the rubber boot and Figure 8-83. Install Cardboard Insert
plunger of the Front Stoplight Switch.

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LEFT HANDLEBAR CONTROLS

7958
1. Using a T27 TORX drive head, remove the two screws Upper
with flat washers securing the handlebar clamp to the Switch Housing
clutch lever bracket. Remove the clutch hand lever Cable
assembly and clamp from the handlebar. End
Fittings
2. Using a T25 TORX drive head, remove the upper and
lower switch housing screws.
3. Cut two cable straps to release wire harness conduit
from handlebar.
4. Remove hand grip from handlebar, if damaged. See
Section 2.23 HANDLEBARS, LEFT HAND GRIP,
REMOVAL.

INSTALLATION
Figure 8-85. Route Cable to Upper Switch Housing

NOTE
While there are four different switch configurations for Touring Note the different diameter inserts crimped into the end
models (Road King, Road King Classic, Classic and Ultra), of the throttle and idle control cable housings. See Fig-
the installation procedures are the same. To simplify these ure 8-84.
instructions, only the Road King switch configuration is repre-
Push the larger diameter insert (silver) on the throttle
sented in the photographs and illustrations which follow.
cable housing into the larger hole in front of the tension
adjuster screw.
RIGHT HANDLEBAR CONTROLS Push the smaller diameter insert (gold) on the idle cable
1. With the concave side facing upward, install the friction housing into the smaller hole at the rear of the tension
shoe so that the pin hole is over the point of the adjuster adjuster screw.
screw (non cruise equipped models only).
NOTE
NOTE To aid assembly, place a drop of light oil on the retaining
The friction shoe is a loose fit and may fall out or become dis- rings of the crimped inserts. Always replace the retaining
lodged if the switch housing is turned upside down or rings if damaged or distorted.
shaken.
3. Route the cable to the upper switch housing as shown in
2. Push the throttle and idle control cables into the lower Figure 8-85.
switch housing until they snap in place. Proceed as fol-
lows: 4. Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 inch (3.2 mm).
7961
5. Position the lower switch housing beneath the throttle
Lower control grip. Install the brass ferrules onto the cables so
Switch that the end fittings seat in the ferrule recess. Seat the
Housing ferrules in their respective notches on the throttle control
grip. Verify that the cables are captured in the grooves
molded into the grip. See Figure 8-86.
6. Position the upper switch housing over the handlebar
Throttle and lower switch housing.
Cable Insert
7. Verify that the wire harness conduit runs in the depres-
(Silver)
sion at the bottom of the handlebar. Be sure that the
Idle upper switch housing harness will not be pinched under
Cable Insert the handlebar when the switch housing screws are tight-
(Gold)
ened.

Figure 8-84. Install Throttle/Idle Control Cables 8. Start the upper and lower switch housing screws, but do
in Lower Switch Housing not tighten.

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f1474x2x Idle CAUTION

Throttle Cable
Cable See Figure 8-87. Do not remove the 5/32 inch (4.0 mm)
cardboard insert (or cable strap eyelet) wedged between
the brake lever and lever bracket. Removal will result in
damage to the rubber boot and plunger of the Front
Throttle Stoplight Switch during installation of the master cylin-
Grip der assembly.

9. Position the brake lever/master cylinder assembly

inboard of the switch housing assembly engaging the
tab on the lower switch housing in the groove at the top
of the brake lever bracket. See Figure 8-88.
10. Align the holes in the handlebar clamp with those in the
master cylinder housing and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Nm) using a T27 TORX drive head.
11. Using a T25 TORX drive head, tighten the lower and
upper switch housing screws to 35-45 in-lbs (4-5 Nm).

NOTE
Always tighten the lower switch housing screw first so that
any gap between the upper and lower housings is at the front
of the switch.
Groove Notch Ferrule
12. Remove the cardboard insert between the brake lever
Figure 8-86. Install Throttle/Idle Control Cables on and lever bracket.
Throttle Control Grip The completed assembly appears as shown in Figure 8-
91.

f1225x2x 13. Secure wire harness conduit to handlebar using two

new cable straps. Position first cable strap approxi-
mately 4-5 inches (102-127 mm) from handlebar clamp.
Cut any excess cable strap material.
14. Test the switches for proper operation.
Groove

f1785x8x
Brake
Lever
Bracket
Tab
Groove

5/32 Inch
(4.0 mm)
Cardboard
Insert

Switch
Housing
Assembly

Figure 8-87. Leave Cardboard Insert in Place Figure 8-88. Fit Brake Lever/Master Cylinder to
Right Handlebar Switch Housings

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7964
7966

Tab

Groove
Switch
Grip Clutch Housing
Sleeve Lever Assembly
Ribs
Bracket

Figure 8-90. Fit Clutch Lever Bracket to

Left Handlebar Switch Housings
Grooves

7. Using a T25 TORX drive head, tighten the lower and

upper switch housing screws to 35-45 in-lbs (4-5 Nm).

Figure 8-89. Install Left Handlebar Switch Housings NOTE

Always tighten the lower switch housing screw first so that
any gap between the upper and lower housings is at the front
LEFT HANDLEBAR CONTROLS
of the switch.

1. Install new hand grip, if removed,. See Section 2.23 The completed assembly appears as shown in Figure 8-
HANDLEBARS, LEFT HAND GRIP, INSTALLATION. 91.

2. Install upper and lower switch housings on handlebar. 8. Secure wire harness conduit to handlebar using two
Be sure that ribs on outboard side of switch housings fit new cable straps. Position first cable strap approxi-
in grooves molded into grip. See Figure 8-89. mately 4-5 inches (102-127 mm) from handlebar clamp.
Cut any excess cable strap material.
3. Verify that the wire harness conduit runs in the groove at
9. Test the switches for proper operation.
the bottom of the handlebar. Be sure that the upper
switch housing harness will not be pinched under the
handlebar when the switch housing screws are tight-
ened.

4. Start the upper and lower switch housing screws, but do

not tighten.

5. Position the clutch hand lever assembly inboard of the

switch housing assembly engaging the tab on the lower
switch housing in the groove at the bottom of the clutch
lever bracket. See Figure 8-90.

6. Align the holes in the handlebar clamp with those in the

clutch lever bracket and start the two screws (with flat
washers). Position for rider comfort. Beginning with the
top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Nm) using a T27 TORX drive head.

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f1228a2x

Right Handlebar Switch Housings

Upper Switch Housing:
● Engine Start Switch
● Engine Stop Switch: Off/Run
Lower Switch Housing:
● Turn-Right Signal Switch
● Front Stoplight Switch

Left Handlebar Switch Housings

Upper Switch Housing:
● Horn Switch
● Light Switch: Hi(gh) and Lo(w) Beam
Lower Switch Housing:
● Turn-Left Signal Switch
f1227a2x

Figure 8-91. Road King Handlebar Switch Assemblies

Right Handlebar Switch Housings f2158x8x

Upper Switch Housing:

● Engine Start Switch
● Engine Stop Switch: Off/Run
Lower Switch Housing:
● Turn-Right Signal Switch
● Front Stoplight Switch
● Cruise Control Switch: Set/Res(ume)

Left Handlebar Switch Housings

Upper Switch Housing:
● Horn Switch
● Light Switch: Hi(gh) and Lo(w) Beam
Lower Switch Housing:

f2157x8x
● Turn-Left Signal Switch
● Cruise Control Switch: On/Off

Figure 8-92. Road King Classic Handlebar Switch Assemblies

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f1370a8x
Right Handlebar Switch Housings
Upper Switch Housing:
● Engine Start Switch
● Engine Stop Switch: Off/Run
Lower Switch Housing:
● Turn-Right Signal Switch
● Front Stoplight Switch
● Mode Select Switch: UP/DN

Left Handlebar Switch Housings

Upper Switch Housing:
● Horn Switch
● Light Switch: Hi(gh) and Lo(w) Beam
Lower Switch Housing:
f1369a8x
● Turn-Left Signal Switch
● Audio Control Switch: +/-

Figure 8-93. Classic Handlebar Switch Assemblies

f1368a8x
Right Handlebar Switch Housings
Upper Switch Housing:
● Engine Start Switch
● Engine Stop Switch: Off/Run
Lower Switch Housing:
● Turn-Right Signal Switch
● Front Stoplight Switch
● Mode Select Switch: UP/DN
● Cruise Control Switch: Set/Res(ume)

Left Handlebar Switch Housings

Upper Switch Housing:
● Horn Switch
● Light Switch: Hi(gh) and Lo(w) Beam
Lower Switch Housing:
● Turn-Left Signal Switch
● Audio Control Switch: +/-
f1367a8x ● Squelch Control and Driver P(ush)
T(o) T(ransmit) Switch: SQ-/PTT/SQ+

Figure 8-94. Ultra Handlebar Switch Assemblies

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SWITCH REPAIR/REPLACEMENT 3. Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the clutch lever bracket.
Remove the lower clamp screw with flat washer.
RIGHT SIDE HANDLEBAR SWITCHES 4. See SPECIFIC REPAIR PROCEDURES, UPPER
SWITCH HOUSINGS for upper switch housing switches,
DISASSEMBLY LOWER SWITCH HOUSINGS for lower switch housing
switches.
CAUTION

Do not remove the switch housing assembly without first

placing the 5/32 inch (4.0 mm) cardboard insert between SPECIFIC REPAIR PROCEDURES
the brake lever and lever bracket. Removal without the
insert may result in damage to the rubber boot and
plunger of the Front Stoplight Switch. NOTE
Regardless of model or option, all vehicles use the same
NOTE
upper switch housings.
Use the eyelet of an ordinary cable strap if the cardboard
insert is not available. UPPER SWITCH HOUSINGS
1. Place the cardboard insert between the brake lever and
lever bracket.
NOTE
2. Using a T25 TORX drive head, remove the upper and Replace the Engine Stop and Engine Start Switches as a
lower switch housing screws. single assembly even if only one switch is determined to be
3. If replacing lower housing switches, proceed to step 4. If faulty.
replacing upper housing switches, proceed to step 8.
RIGHT SIDE HANDLEBAR (ALL MODELS)
4. Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the master cylinder ● Engine Stop Switch: OFF/RUN
housing. Remove the lower clamp screw with flat ● Engine Start Switch
washer.
[Continued from RIGHT SIDE HANDLEBAR
5. Remove the brass ferrules from the notches on the
SWITCHES, DISASSEMBLY, on this page.]
inboard side of the throttle control grip. Remove the fer-
rules from the cable end fittings. 1. From inside the switch housing, remove the Phillips
screw to release the bracket. Remove the bracket and
6. Remove the friction shoe from the end of the tension
switch assembly from the housing. See Figure 8-95.
adjuster screw (non cruise equipped models only).
2. Move cable conduit from beneath wing of bracket. Cut
NOTE wires 1/4 inch (6.4 mm) from old switches. Discard old
The friction shoe is a loose fit and may fall out or become dis- switch and bracket assembly.
lodged if the lower switch housing is turned upside down or
shaken. 3. Slide conduit forward over severed ends of switch wires
and cut off 1/2 inch (12.7 mm) of conduit material. Push
7. Remove the throttle control grip from the end of the han- conduit back to access switch wires.
dlebar. 4. Separate new Engine Stop Switch and Start Switch
8. See SPECIFIC REPAIR PROCEDURES, UPPER wires into two bundles.
SWITCH HOUSINGS for upper switch housing switches,
LOWER SWITCH HOUSINGS for lower switch housing NOTE
switches. Replacement Stop Switch and Start Switch wires are cut to
length (2-1/2 inches and 2 inches, respectively) and partially
stripped.

LEFT SIDE HANDLEBAR SWITCHES 5. See GENERAL REPAIR PROCEDURES in this section.

DISASSEMBLY 6. Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-96. Route wires downstream of
1. Using a T25 TORX drive head, remove the upper and splices beneath wing on Engine Stop Switch side of
lower switch housing screws. bracket as seen in Figure 8-95.
2. If replacing lower housing switches, proceed to step 3. If 7. Install a new 7 inch cable strap beneath wing on Engine
replacing upper housing switches, proceed to step 4. Start Switch side of bracket and capture wire splices.

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f1271x2x

Screw
Splices

Start Stop Start Stop

Switch Switch Switch Switch

Bracket

Wing

Channel Cable
Conduit Strap Conduit
f1272x2x

Figure 8-95. Upper Right Handlebar Switch Housing Figure 8-96. Upper Right Handlebar Switch Housing
(Without Splices) (With Splices)

8. Place switch assembly into upper housing aligning hole 2. Move cable conduit from beneath wing of bracket. Cut
in bracket with threaded hole in boss. Be sure that wires 1/4 inch (6.4 mm) from old switches. Discard old
bracket is fully seated. The step at the edge of the boss switch and bracket assembly.
captures the bottom edge of the bracket, while tabs on
each side of the bracket fit in slots cast into the housing. 3. Slide conduit forward over severed ends of switch wires
and cut off 1/2 inch (12.7 mm) of conduit material. Push
9. Install Phillips screw to secure bracket inside housing. conduit back to access switch wires.
Verify that wing on Engine Stop Switch side of bracket
captures edge of conduit as shown in Figure 8-95. 4. Separate new Horn and High/Low Beam Switch wires
10. Securely tighten cable strap to draw splices to bracket. into two bundles.
Remove any excess cable strap material.
NOTE
11. See RIGHT SIDE HANDLEBAR SWITCHES, ASSEM-
BLY, in this section. Replacement High/Low Beam Switch and Horn Switch wires
are cut to length (2-1/2 inches and 2 inches, respectively)
NOTE and partially stripped.
Replace the Horn and High/Low Beam Switches as a single
assembly even if only one switch is determined to be faulty. 5. See GENERAL REPAIR PROCEDURES in this section.

6. Loop switch wires so that spliced lengths are positioned

as shown in Figure 8-98. Route wires downstream of
LEFT SIDE HANDLEBAR (ALL MODELS) splices beneath wing on High/Low Beam Switch side of
bracket as seen in Figure 8-97.
● Hi(gh) and Lo(w) Beam Switch

● Horn Switch 7. Install a new 7 inch cable strap beneath wing on Horn
Switch side of bracket and capture wire splices.
[Continued from LEFT SIDE HANDLEBAR SWITCHES,
DISASSEMBLY, in this section.] 8. Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that
1. See Figure 8-97. From inside the switch housing, bracket is fully seated. The step at the edge of the boss
remove Phillips screw to release the bracket. Remove captures the bottom edge of the bracket, while tabs on
the bracket and switch assembly from the housing. each side of the bracket fit in slots cast into the housing.

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f1269x2x
Screw

Horn Beam Horn Beam

Switch Switch Switch Switch

Bracket

Wing

Cable Splices
f1270x2x Conduit Strap

Figure 8-97. Upper Left Handlebar Switch Housing Figure 8-98. Upper Left Handlebar Switch Housing
(Without Splices) (With Splices)

9. Install Phillips screw to secure bracket inside housing. ● Turn-Right Signal Switch
Verify that wing on High/Low Beam Switch side of (All Models)
bracket captures edge of conduit as shown in Figure 8-
97. 1. Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-
card old switch assembly.
10. Securely tighten cable strap to draw splices to bracket.
Remove any excess cable strap material. See Figure 8- NOTE
98. Replacement Turn-Right Signal Switch wires are cut to length
11. See LEFT SIDE HANDLEBAR SWITCHES, ASSEM- (1-1/2 inches) and partially stripped.
BLY, in this section. 2. See GENERAL REPAIR PROCEDURES in this section.
3. See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-
LOWER SWITCH HOUSINGS TIONS in this section.
RIGHT SIDE HANDLEBAR
PRELIMINARY INSTRUCTIONS ● Front Stoplight Switch
(All Models)
[Continued from RIGHT SIDE HANDLEBAR
SWITCHES, DISASSEMBLY, in this section.] 1. Carefully remove the wedge between the switch and
switch housing, if present. To remove the switch from the
1. From inside the switch housing, carefully cut cable strap
housing, depress the plunger and slowly rotate switch
to free conduit from the turn signal switch bracket, if
upward while rocking slightly.
present.
2. Cut wires 1 inch (25.4 mm) from old switch. Discard old
2. Remove the Phillips screw to release the turn signal
switch.
switch bracket. Remove the bracket and switch assem-
bly from the housing. NOTE
NOTE Replacement Stoplight Switch wires are cut to length (2-1/2
On Classic and Ultra models, pull the conduit back to intro- inches) and partially stripped.
duce some slack in the wires or the tight fit of the bundle will 3. See GENERAL REPAIR PROCEDURES in this section.
prevent removal of the turn signal switch bracket.

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4. Carefully depress plunger against inside wall of switch

housing. With thumb over plunger bore, move switch into Lower Bracket
the installed position in the switch housing cavity. When Screw
plunger is positioned against thumb, slowly rotate switch Turn Signal Switch
Bracket Screw
downward while rocking slightly. Release the plunger
only after switch is properly positioned in the cavity.
5. Verify that the plunger is square in the bore and that the
boot is not compressed, collapsed or torn. If necessary,
gently work the plunger in and out until boot is fully
extended.
6. Push down on switch so that it bottoms against housing
and wires run in groove at base of cavity. With the con-
cave side facing outward, insert wedge between switch
and outboard side of switch housing. See Figure 8-99.
7. Push wedge down until it also bottoms against housing.
Verify that the plunger is still square in the bore and then
place a drop of RTV Silicone Sealant on upper corner of
wedge.
8. See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-
TIONS on the next page.

● Mode Select Switch

(Classic and Ultra Models)
1. Pull keycap from switch shaft. Cable
Strap
2. Remove two lower bracket screws. Pull bracket and Lower Bracket
switch from switch housing. See Figure 8-100. Screw
f1309x2x

Figure 8-100. Lower Right Handlebar Switch Housing

f1280x2x Cavity (Without Splices) - Classic/Ultra Models
Wedge
3. Cut wires 1-1/4 inches (31.8 mm) from old switch. Dis-
card switch assembly.
NOTE
Lower
Replacement Mode Select Switch wires are cut to length (2-
Switch
Housing 1/4 inches) and partially stripped.
4. See GENERAL REPAIR PROCEDURES in this section.
Stoplight
Switch 5. Fit new switch into cavity so that it sits on edge in a verti-
cal position (gray/white wire topside). Properly installed,
the switch is captured by blocks cast into the lower hous-
ing. Verify that the switch shaft is aligned for proper key-
cap operation.
6. Place the lower bracket into the housing (with the weld
nut side down), but keep the splices above the bracket.
Verify that the slots in the upper step of the bracket
engage two tabs on switch body.
Groove
Switch 7. Install shorter screw to secure front side of lower bracket
Wires to threaded boss. Install longer rear screw. To engage
threaded hole in casting, use thru hole in lower step of
bracket on Classic models, thru hole in upper step on
Ultra.
8. Install keycap on switch shaft.
9. See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-
Figure 8-99. Install Stoplight Switch
TIONS on the next page.

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7. Install shorter screw to secure front side of lower bracket
f1294x2x 7 Inch to threaded boss. Install longer rear screw. Use thru hole
Cable Strap in upper step of bracket to engage threaded hole in cast-
ing.
Bracket 8. Note lettering for proper orientation and gently push key-
cap onto switch shaft.
9. See RIGHT SIDE HANDLEBAR, FINAL INSTRUC-
TIONS on this page.

RIGHT SIDE HANDLEBAR

FINAL INSTRUCTIONS
1. Insert tapered end of new 7 inch cable strap into round
hole in turn signal switch bracket and then feed back
through using the adjacent hole. Reserve the oblong
hole for the bracket screw. See Figure 8-101.

NOTE
Right Turn
Signal Switch Be sure that all splices are positioned above the turn signal
switch bracket.

2. Place the turn signal switch assembly into the housing

aligning the oblong hole in the bracket with the lower
bracket weld nut (threaded boss on Road King Standard
Figure 8-101. Insert Cable Strap in Switch Bracket models). Be sure that bracket is fully seated. Tabs on
each side of bracket are captured in slots cast into
switch housing.
● Cruise Set/Resume Switch
(Road King Classic and Ultra Models) 3. Start Phillips screw to secure bracket inside housing.

1. Pull keycap from switch shaft.

CAUTION
2. Remove two lower bracket screws. Pull bracket and
switch from switch housing. If routed incorrectly, wires may be pinched by casting or
handlebar resulting in switch failure.
3. Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-
card switch assembly. 4. Loop switch wires so that spliced lengths are positioned
NOTE as shown in Figure 8-102.
Replacement Cruise Set/Resume Switch wires are cut to 5. Capturing conduit about 1/4 inch (6.4 mm) from end,
length (2 inches) and partially stripped. securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.
4. See GENERAL REPAIR PROCEDURES in this section.
5. Fit new switch into cavity so that it sits in a horizontal 6. Install second 7 inch cable strap capturing conduit and
position (blue/black wire towards master cylinder). Prop- wire splices. Securely tighten cable strap to draw splices
erly installed, the switch is captured by blocks cast into to conduit. Remove any excess cable strap material.
the lower housing. 7. Tighten Phillips screw to secure bracket inside housing.
6. Keeping splices above the bracket, install the lower
8. Route wire bundle to upper switch housing by gently
bracket (weld nut side down), so that the lower step is
pressing conduit into channel next to angular arm of
positioned over the switch. Slots in the upper step
bracket. Secure bundle to arm using third cable strap.
engage two tabs on the Cruise On Lamp upper housing
(Road King Classic), or the body of the Mode Select Cut any excess cable strap material. If necessary, bend
Switch (Ultra models). angular arm of bracket downward to firmly secure Front
Stoplight Switch in installed position.
NOTE
The Mode Select Switch is vertically oriented with the gray/ 9. See RIGHT SIDE HANDLEBAR SWITCHES, ASSEM-
white wire topside. BLY, in this section.

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f1311x2x Angular f1311x2x

Angular
Arm Cable Strap Arm Cable Strap
(Wire Bundle to Arm) (Wire Bundle to Arm)

Splices
Splices

Cable Strap Cable Strap

Cable Strap (Conduit to Bracket) Cable Strap (Conduit to Bracket)
(Splices to Conduit) (Splices to Conduit)

MODE SELECT SWITCH CRUISE CONTROL SWITCH

Figure 8-102. Lower Right Handlebar Switch Housing (With Splices) - Classic/Ultra Models

LEFT SIDE HANDLEBAR NOTE

Replacement Turn-Left Signal Switch wires are cut to length
PRELIMINARY INSTRUCTIONS (1-1/2 inches) and partially stripped.
[Continued from LEFT SIDE HANDLEBAR SWITCHES,
2. See GENERAL REPAIR PROCEDURES in this section.
DISASSEMBLY, in this section.]
3. See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS
1. From inside the switch housing, carefully cut cable strap
on the next page.
to free conduit from the turn signal switch bracket, if
present.
● Audio Control Switch
2. Remove the Phillips screw to release the turn signal (Classic and Ultra Models)
switch bracket. Remove the bracket and switch assem-
bly from the housing. 1. Pull keycap from switch shaft.

NOTE 2. Remove two lower bracket screws. See Figure 8-105.

On Classic and Ultra models, pull the conduit back to intro- Pull bracket and switch from switch housing.
duce some slack in the wires or the tight fit of the bundle will 3. Cut wires 1-1/4 inches (31.8 mm) from old switch. Dis-
prevent removal of the switch bracket. card switch assembly.

● Turn-L(eft) Signal Switch NOTE

(All Models) Replacement Audio Control Switch wires are cut to length (2-
1/4 inches) and partially stripped.
1. Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-
card old switch assembly. 4. See GENERAL REPAIR PROCEDURES in this section.

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Stoplight
Switch
Turn Signal Switch
and Bracket

Turn Signal Switch

and Bracket
Lower
Bracket Lower
Audio Control Bracket
Switch Mode Select
Switch

Mode Select
Audio Switch Keycap
Keycap

Classic Models f1327x2x Classic Models f1326x2x

Stoplight Turn Signal Switch

Turn Signal Switch Switch and Bracket
and Bracket

Cruise
Control Switch

PTT
Switch

Lower
Bracket Lower
Bracket
Audio
Control Mode
Switch Cruise Select Switch
Switch Keycap
PTT Switch
Keycap

Mode Select
Keycap
Audio Switch
Ultra Models Keycap f1329x2x Ultra Models f1328x2x

Figure 8-103. Lower Left Handlebar Switch Assemblies Figure 8-104. Lower Right Handlebar Switch Assemblies
(Exploded View) (Exploded View)

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2. Remove two lower bracket screws. See Figure 8-105.

Pull bracket and switch from switch housing.
Lower Bracket Turn Signal Switch
Screw Bracket Screw 3. Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-
card switch assembly.

NOTE
Replacement Push-to-Transmit Switch wires are cut to length
(2 inches) and partially stripped.

4. See GENERAL REPAIR PROCEDURES in this section.

5. Fit new switch into cavity so that it sits in a horizontal
position (brown/black wire towards clutch lever bracket).
Properly installed, the switch is captured by blocks cast
into the lower housing.
6. Keeping splices above the bracket, install the lower
bracket (weld nut side down) so that the lower step is
positioned over the Push-to-Transmit Switch (horizon-
tally oriented). Slots in the upper step engage two tabs
on body of Audio Control Switch (vertically oriented with
gray wire topside).
Cable 7. Install shorter screw to secure front side of lower bracket
Strap to threaded boss. Install longer rear screw. To engage
threaded hole in casting, use thru hole in upper step of
bracket.
8. Note lettering for proper orientation and gently push key-
Lower Bracket cap onto switch shaft.
Screw 9. See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS
f1306x2x
on this page.

Figure 8-105. Lower Left Handlebar Switch Housing

(Without Splices) - Classic/Ultra Models ● Cruise On/Off Switch
(Road King Classic Models)

5. Fit new switch into cavity so that it sits on edge in a verti- 1. Pull keycap from switch shaft.
cal position (gray/green wire topside). Properly installed, 2. Remove two lower bracket screws. Pull bracket and
the switch is captured by blocks cast into the lower hous- switch from switch housing.
ing. Verify that the switch shaft is aligned for proper key-
3. Cut wires 1-1/2 inches (38.1 mm) from old switch. Dis-
cap operation.
card switch assembly.
6. Place the lower bracket into the housing (with the weld
nut side down), but keep the splices above the bracket. NOTE
Verify that the slots in the upper step of the bracket Cut replacement Cruise On/Off Switch wires to 2 inches and
engage two tabs on switch body. strip 1/2 inch of insulation.
7. Install shorter screw to secure front side of lower bracket 4. See GENERAL REPAIR PROCEDURES in this section.
to threaded boss. Install longer rear screw. To engage
threaded hole in casting, use thru hole in lower step of 5. Fit new switch into cavity so that it sits in a horizontal
bracket on Classic models, thru hole in upper step on position (orange/white wire towards clutch lever bracket).
Ultra. Properly installed, the switch is captured by blocks cast
into the lower housing.
8. Note lettering for proper orientation and gently push key-
cap onto switch shaft. 6. Keeping splices above the bracket, install the lower
bracket (weld nut side down), so that the lower step is
9. See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS positioned over the switch. Slots in the upper step
on the next page. engage two tabs on the Cruise On Lamp upper housing.
7. Install shorter screw to secure front side of lower bracket
● CB Push-To-Transmit Switch (Ultra Models) to threaded boss. Install longer rear screw. Use thru hole
in upper step of bracket to engage threaded hole in cast-
1. Pull keycap from switch shaft. ing.

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4. Loop switch wires so that spliced lengths are positioned

f1295x2x
as shown in Figure 8-107.
7 Inch
Cable Strap 5. Capturing conduit about 1/4 inch (6.4 mm) from end,
Bracket securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.
6. Tighten Phillips screw to secure bracket inside housing.
7. Route wire bundle to upper switch housing below and
then forward of the main wire harness positioning con-
duit in channel next to angular arm of bracket. See Fig-
ure 8-107. Secure bundle to arm using new cable strap.
Cut any excess cable strap material.
8. See LEFT SIDE HANDLEBAR SWITCHES, ASSEM-
BLY, which follows.

GENERAL REPAIR PROCEDURES

Left Turn
Signal Switch 1. To better access wires and avoid damaging conduit with
radiant heating device, push conduit back and secure
with extra 7 inch cable strap in kit.

Figure 8-106. Insert Cable Strap in Switch Bracket

Angular
8. Note lettering for proper orientation and gently push key- Arm
Splices Cable
cap onto switch shaft.
Strap
9. See LEFT SIDE HANDLEBAR, FINAL INSTRUCTIONS
below.

LEFT SIDE HANDLEBAR

FINAL INSTRUCTIONS
1. Insert tapered end of new 7 inch cable strap into round
hole in turn signal switch bracket and then feed back
through using the adjacent hole. Reserve the oblong
hole for the bracket screw. See Figure 8-106.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
2. Place the turn signal switch assembly into the housing
aligning the oblong hole in the bracket with the lower
bracket weld nut (threaded boss on Road King Standard
models). Be sure that bracket is fully seated. Tabs on
each side of bracket are captured in slots cast into
switch housing.
3. Start Phillips screw to secure bracket inside housing. Cable
Strap
f1310x2x
CAUTION

If routed incorrectly, wires may be pinched by casting or Figure 8-107. Lower Left Handlebar Switch Housing
handlebar resulting in switch failure. (With Splices) - Classic/Ultra Models

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f1313x2x 1WARNING
Use extreme caution when operating the UltraTorch UT-
A 100 or any other radiant heating device. Read the manu-
facturers instructions carefully before use. Always keep
hands away from tool tip area and heat shrink attach-
ment. Avoid directing the heat toward any fuel system
component. Extreme heat can cause fuel ignition/explo-
sion. Avoid directing heat toward any electrical system
component other than the connectors on which heat
shrink work is being performed. Be sure to turn the “ON/
OFF” switch to the “OFF” position after use. Inadequate
B safety precautions could result in death or serious
injury.

6. See Figure 8-109. Using the UltraTorch UT-100, Robinair

Heat Gun with heatshrink attachment or other suitable
radiant heating device, uniformly heat the heat-shrink
C tubing to insulate and seal the soldered connections.
Apply heat just until the meltable sealant exudes out
both ends of the tubing and it assumes a smooth cylin-
Figure 8-108. Splice Switch Wires drical appearance.

CAUTION
2. Strip 1/2 inch of insulation off switch wires. Twist stripped Electrically connected solder outside the tubing may
ends of switch wires until all strands are tightly coiled. cause a short to ground resulting in switch failure.
3. Cut dual wall heat-shrink tubing supplied in kit into one
7. Inspect the melted sealant for solder beads. Excess sol-
inch (25.4 mm) segments. Slide tubing over each wire of
der or heat may force some solder out with the melted
new switch assembly.
sealant. Use a small needle nose pliers to remove any
NOTE solder found. Briefly heat the connection to reseal the
tubing if solder beads were removed. Use less solder or
If absent from kit, obtain heat shrink tubing (Part No. 72266- reduce heating time or intensity when doing subsequent
94) and two 7 inch cable straps (Part No. 10181). splices.
4. Matching wire colors, mate old and new switch wires and
splice as follows:
a. Hold the wires so that the stripped ends cross as
shown in A of Figure 8-108. Note that the wire on
the left is on top and two-thirds of its stripped length
lies beyond the point where they intersect. Looking
at the other wire, only 1/3 of its stripped length lies Ultra Torch UT-100
beyond the intersection point. (HD-39969)

b. Holding the wires together at their juncture, start the

splice by tightly twisting the top one-third length of
the right hand wire over the left as shown in B of
Figure 8-108.
c. Tightly coil the remaining two-thirds of the left hand
wire around the right with the results shown in C of
Figure 8-108.
d. Solder the spliced connections. Robinair Heat Gun
Shrink Tool Attachment
NOTE Robinair Heat Gun (HD-41183))
For best results, do one wire at a time. (HD-25070)

5. Center the heat-shrink tubing over the soldered splices. Figure 8-109. Radiant Heating Devices

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8. Cut cable strap compressing conduit and move to its LEFT SIDE HANDLEBAR SWITCHES
original position.
ASSEMBLY
1. If replacing lower housing switches, proceed to step 2. If
RIGHT SIDE HANDLEBAR SWITCHES replacing upper housing switches, proceed to step 6.
ASSEMBLY 2. Install upper and lower switch housings on handlebar.
Be sure that ribs on outboard side of switch housings fit
1. If replacing lower housing switches, proceed to step 2. If
in grooves molded into grip. Verify that the wire harness
replacing upper housing switches, proceed to step 9.
conduit runs in the depression at the bottom of the han-
2. With the concave side facing upward, install the friction dlebar.
shoe so that the pin hole is over the point of the adjuster
3. Start the upper and lower switch housing screws, but do
screw (non cruise equipped models only).
not tighten.
NOTE
4. Position the clutch hand lever assembly inboard of the
The friction shoe is a loose fit and may fall out or become dis- switch housing assembly engaging the tab on the lower
lodged if the lower switch housing is turned upside down or switch housing in the groove at the bottom of the clutch
shaken. lever bracket.
3. Slide the throttle control grip over the end of the right 5. Align the holes in the handlebar clamp with those in the
handlebar until it bottoms against the closed end. Rotate clutch lever bracket and start the lower screw (with flat
the grip so that the ferrule notches are at the top. To pre- washer). Position for rider comfort. Beginning with the
vent binding, pull the grip back about 1/8 inch (3.2 mm). top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
4. Position the lower switch housing beneath the throttle Nm) using a T27 TORX drive head.
control grip. Install the brass ferrules onto the cables so 6. Using a T25 TORX drive head, tighten the lower and
that the end fittings seat in the ferrule recess. Seat the upper switch housing screws to 35-45 in-lbs (4-5 Nm).
ferrules in their respective notches on the throttle control
grip. Verify that the cables are captured in the grooves NOTE
molded into the grip. Always tighten the lower switch housing screw first so that
5. Position the upper switch housing over the handlebar any gap between the upper and lower housings is at the front
and lower switch housing. Verify that the wire harness of the switch assembly.
conduit runs in the depression at the bottom of the han-
dlebar. 7. Test the switches for proper operation.

6. Start the upper and lower switch housing screws, but do

not tighten.
7. Position the brake lever/master cylinder assembly
inboard of the switch housing assembly engaging the
tab on the lower switch housing in the groove at the top
of the brake lever bracket.
8. Align the holes in the handlebar clamp with those in the
master cylinder housing and start the lower screw (with
flat washer). Position for rider comfort. Beginning with
the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Nm) using a T27 TORX drive head.
9. Using a T25 TORX drive head, tighten the lower and
upper switch housing screws to 35-45 in-lbs (4-5 Nm).
NOTE
Always tighten the lower switch housing screw first so that
any gap between the upper and lower housings is at the front
of the switch assembly.
10. Remove the cardboard insert between the brake lever
and lever bracket.
11. Test the switches for proper operation.

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STOPLIGHT SWITCHES 8.22

FRONT STOPLIGHT SWITCH NOTE

The front and rear stoplight switches “trigger” a relay that
To replace the front stoplight switch, refer to Section 8.21 connects 12 vdc to the stoplights. The stoplight (brake light)
HANDLEBAR SWITCHES, SWITCH REPAIR/REPLACE- relay is located under the seat.
MENT.
NOTE
On Ultra models the stoplight switches also disengage the
REAR STOPLIGHT SWITCH cruise control when either switch closes.

The switch is mounted in a tee in the rear brake line. The tee
is attached to a frame weldment on the right lower frame
tube. If the stoplight fails to light when the rear brake is
applied, check the bulb. If bulb is OK, check the continuity of
the brake light wires. If brake light wires are good, check the
stoplight switch for continuity with pedal depressed. Replace
the switch if defective. See Section 2.11 REAR BRAKE MAS-
TER CYLINDER, REAR BRAKE LINE, REMOVAL/INSTAL-
LATION.

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NEUTRAL SWITCH 8.23

GENERAL

A two terminal neutral switch (normally closed) is mounted to

the transmission top cover. When the transmission is in NEU-
TRAL and the Ignition/Light Key Switch is in the IGNITION
position, the neutral indicator lamp illuminates to indicate this
condition to the rider.

REMOVAL O-Ring

f2236x8x
CAUTION

Cover transmission top cover with masking tape to pre-

Figure 8-110. Neutral Switch Assembly
vent damage to chrome.

1. Using fingers and flat tip screwdriver, remove two elbow

connectors from neutral switch posts. 3. Using 7/8 inch box and open end wrench, install neutral
switch with O-ring in the transmission top cover. Tighten
2. Using 7/8 inch box and open end wrench, remove neu- to 120-180 in-lbs (13.6-20.3 Nm).
tral switch and O-ring from transmission top cover.
4. Using fingers and a flat tip screwdriver, install the two
elbow connectors on neutral switch posts.
NOTE
If neutral switch connector is damaged, replace using Part NOTE
No.’s 72405-98BK or 72405-98TN with a heat-sealed butt The neutral switch is not polarity sensitive, so the elbow con-
splice connector. For detailed butt splicing information, see nectors can be attached to either stud.
APPENDIX B.5 SEALED BUTT SPLICE CONNECTORS.
5. Test neutral switch for proper operation as follows:

INSTALLATION a. Turn the Ignition/Light Key Switch to the IGNITION

position.

b. Verify that neutral indicator lamp illuminates.

NOTE
If transmission top cover has been removed, be sure to install 6. Remove masking tape from transmission top cover.
neutral switch after top cover installation to ensure proper
switch engagement.

1. Roll the vehicle back and forth to verify that the transmis-
sion is in NEUTRAL.

2. Lubricate O-ring with clean transmission oil.

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OIL PRESSURE SWITCH/SENDER 8.24

REMOVAL INSTALLATION

1. Locate the oil pressure switch/sender at the front right

NOTE
side of the crankcase.
If reusing oil pressure switch/sender, apply Loctite Pipe Seal-
2. Proceed as follows: ant with Teflon 565 to threads.
FLHR/C/S: Pull elbow connector [120] from post termi-
1. Start oil pressure switch/sender into crankcase bore.
nal of oil pressure switch. Use a 15/16 inch Open End
Crow Foot (Snap-On FC30B) to remove switch from 2. Proceed as follows:
crankcase.
FLHR/C/S: Use a 15/16 inch Open End Crow Foot
FLHT/C/U, FLTR: Pull external latch outward and use (Snap-On FC30B) to tighten oil pressure switch to 96-
rocking motion to remove 4-place Packard connector 120 in-lbs (11-14 Nm). Install elbow connector [120] on
[139] from oil pressure sender. Use 1-1/16 inch Open post terminal.
End Crow Foot (Snap-On FC34A) to remove sender
from crankcase. FLHT/C/U, FLTR: Use 1-1/16 inch Open End Crow Foot
(Snap-On FC34A) to tighten oil pressure sender to 96-
120 in-lbs (11-14 Nm). Install 4-place Packard connec-
tor.

3. Test oil pressure switch/sender for proper operation.

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HORN 8.25

TROUBLESHOOTING REMOVAL

1. If the horn does not sound or fails to function satisfacto- 1. Locate the horn below the fuel tank on the left side of the
rily, check for the following conditions. vehicle.
2. Remove acorn nut and flat washer to free horn assembly
● Discharged battery from rubber mount stud.
● Loose, frayed or damaged wiring leading to horn 3. Remove elbow terminals from horn spade contacts.
terminal
4. Remove flange nut (10mm) from circular recess at back
of horn bracket. Remove horn from chrome horn cover.
2. If battery has a satisfactory charge and wiring appears
to be in good condition, check for the following:

● Poor ground to frame through mounting hardware or

ground wire (see Steps 3-6 below) INSTALLATION
● Inoperative horn switch (see Steps 3-6 below)
1. Fit horn into chrome cover so that stud at back slides
through hole in horn bracket. Apply two drops of LOC-
3. Disconnect the YELLOW/BLACK wire at the horn. Con- TITE THREADLOCKER 222 (Purple) to threads of horn
nect a voltmeter as follows: stud.
● Positive (+) lead to wire terminal
● Negative (–) lead to ground CAUTION

Overtightening the flange nut can cause permanent horn

4. Turn ignition switch ON. Depress horn switch. If battery damage resulting in reduced volume and tone quality.
voltage is present, horn or horn grounding is faulty. If
2. Install flange nut (10mm) on horn stud and tighten to 80-
battery voltage is not present, either horn switch or wir-
100 in-lbs (9.0-11.3 Nm).
ing to horn is faulty.
3. Install elbow terminals onto horn spade contacts.
5. Connect an ohmmeter across the horn terminals. The
resistance measured must be 45-66 ohms. Replace
horn if measured resistance is outside range given. NOTE
The horn is not polarity sensitive. Elbow terminals may be
6. If the horn is faulty, then it must be replaced as an attached to either spade contact.
assembly. The horn is not repairable. If the horn switch is
faulty, replace the switch. See Section 8.21 HANDLE- 4. Install horn bracket onto rubber mount stud. Install flat
BAR SWITCHES, SWITCH REPAIR/REPLACEMENT. washer and acorn nut onto stud. Tighten acorn nut to 80-
100 in-lbs (9.0-11.3 Nm).

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CIGARETTE LIGHTER (FLHTCU, FLTR) 8.26

GENERAL 2. Disconnect the socket terminals from the spade contacts

on the cigarette lighter.

FLHTCU and FLTR models are equipped with a cigarette 3. Remove lighter from socket. Holding socket, unscrew
lighter. The lighter is located on the left side of the inner fair- outer shell. Remove socket and outer shell from the fair-
ing. ing.

TROUBLESHOOTING INSTALLATION
1. Ignition/light key switch must be ON or in ACCESSORY 1. From rider side of inner fairing, slide socket of new ciga-
position for lighter operation. rette lighter through bore in fairing. Thread outer shell
2. If lighter does not work, substitute a known good lighter onto socket until tight. Install cigarette lighter in socket.
element. 2. Connect the socket terminals onto the spade contacts of
3. If lighter is still inoperative, check for 12 vdc at center the cigarette lighter. Connect the orange wire terminal to
socket contact and ground at outer shell contact. the center socket spade contact, the black wire terminal
to the outer shell contact.
4. Refer to applicable Wiring Diagram at rear of manual if
12 vdc or ground are not present. Use voltage checks to 3. Install the outer fairing. On FLHTCU models, see Sec-
isolate problem. tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
OUTER FAIRING/WINDSHIELD, INSTALLATION. On
FLTR models, see Section 2.30 UPPER FAIRING/
REMOVAL WINDSHIELD (FLTR), OUTER FAIRING, INSTALLA-
TION.
1. Remove the outer fairing. On FLHTCU models, see Sec-
tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL. On FLTR
models, see Section 2.30 UPPER FAIRING/WIND-
SHIELD (FLTR), OUTER FAIRING, REMOVAL.

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GAUGES/INSTRUMENTS (FLHT/C/U, FLTR) 8.27

GAUGE/LAMP- 2 INCH DIAMETER

Hex Nut
Lamp
Fuel Level, Ambient Air Temperature, Voltmeter, Oil Pin Housing
Pressure

REMOVAL
1. Remove outer fairing. Proceed as follows:

FLHT/C/U: See Section 2.29 UPPER FAIRING/WIND- 8

10 1
2 Mounting
14

SHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD, VO

LT 16
Bracket
REMOVAL. Stud Tab
FLTR: See Section 2.30 UPPER FAIRING/WIND-
SHIELD (FLTR), OUTER FAIRING, REMOVAL. Gauge
f1345x2x
2. Pull 2-place and 3-place socket housings to release
interconnect harness from lamp and gauge, respectively.
Figure 8-111. Voltmeter Gauge Assembly
NOTE
To replace lamp, pull pin housing from gauge and then pull
lamp from slot of pin housing. Install new lamp in slot and GAUGES- 4 INCH DIAMETER
insert pin housing back into gauge. See Figure 8-111.

3. Remove hex nuts from studs. Remove mounting bracket.

TACHOMETER
4. Remove gauge from inner fairing.

REMOVAL

INSTALLATION 1. Proceed as follows:

1. Install gauge in inner fairing. FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
2. Slide mounting bracket over studs. Verify that tabs on top FAIRING/WINDSHIELD, REMOVAL.
and bottom of bracket engage slots in inner fairing. See
Figure 8-111. FLTR: Remove instrument bezel. See Section 2.30
UPPER FAIRING/WINDSHIELD (FLTR), BEZEL,
3. Loosely install hex nuts on studs. Verify that gauge is REMOVAL, steps 1-3.
properly aligned and then tighten nuts to 10-20 in-lbs
(1.1-2.3 Nm). 2. Bend back the external latches slightly and remove
tachometer connector [108], 12-place Packard, at back
4. Install 3-place and 2-place socket housings to connect of tachometer.
interconnect harness to gauge and lamp, respectively.
3. Remove two allen head socket screws to free tachome-
5. Install outer fairing. Proceed as follows: ter bracket from back of tachometer gauge. On FLHT/C/
U models, leave anchors on interconnect harness
FLHT/C/U: See Section 2.29 UPPER FAIRING/WIND-
installed in outboard ears of tachometer bracket.
SHIELD (FLHT/C/U), OUTER FAIRING/WINDSHIELD,
INSTALLATION.
4. Push tachometer gauge toward rear of motorcycle to
FLTR: Section 2.30 UPPER FAIRING/WINDSHIELD remove from inner fairing (FLHT/C/U) or bezel bore
(FLTR), OUTER FAIRING, INSTALLATION. (FLTR).

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INSTALLATION
f2183x8x

1. Insert tachometer gauge into inner fairing (FLHT/C/U) or

bezel bore (FLTR).
2. Align holes in tachometer bracket with those at back of
tachometer gauge and start two allen head socket
screws.
3. Rotate tachometer gauge until tabs at top and bottom of
1
bracket engage slots in inner fairing (FLHT/C/U) or bezel
(FLTR).

NOTE
On FLHT/C/U models, both the speedometer and tachome-
ter brackets are oriented with the ears on the outboard side.
On FLTR models, the brackets are oriented with the ears
inboard.
2
4. Verify that gauge is properly aligned and tighten two
allen head socket screws to 10-20 in-lbs (1.1-2.3 Nm).
5. Install tachometer connector [108], 12-place Packard, at 1. Vehicle Speed Sensor [65]
back of tachometer. 2. P&A Security Siren [142]

6. Proceed as follows: Figure 8-112. Electrical Bracket (Inboard Side)

FLHT/C/U: Verify that anchors on interconnect harness
are installed in lower outboard ears of both the speed-
7951
ometer and tachometer brackets. Install outer fairing.
See Section 2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U), OUTER FAIRING/WINDSHIELD, INSTAL-
LATION. Starter
FLTR: Install instrument bezel. See Section 2.30 Speed
UPPER FAIRING/WINDSHIELD (FLTR), BEZEL, Sensor
INSTALLATION, steps 2-5

VEHICLE SPEED SENSOR

Bolt

REMOVAL
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES, Engine Oil Fill
MAXI-FUSE, REMOVAL. Plug/Dipstick
2. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
Figure 8-113. Vehicle Speed Sensor Location
3. Gently pull side cover from frame downtubes (no tools
required).
NOTE
4. Remove two flange nuts to release electrical bracket For instructions on properly removing wire terminals, see
from studs on side of battery box. APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
5. Disconnect vehicle speed sensor connector [65], 3-place REMOVING/INSTALLING PINS.
Deutsch, on the inboard side of the electrical bracket.
7. Carefully cut anchored cable strap inboard of rear pas-
See Figure 8-112.
senger footboard screw to release cable from frame
6. Remove terminals from pin housing. downtube.

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8. Locate the vehicle speed sensor mounted next to the 10. Install right side saddlebag. See Section 2.25 SADDLE-
starter on the right side of the transmission case. BAG, INSTALLATION.
Remove the bolt to free the sensor from the case. See
11. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
Figure 8-113.
MAXI-FUSE, INSTALLATION.
9. Draw sensor and cable forward to remove from motorcy-
cle.

SPEEDOMETER
INSTALLATION
1. Inspect the vehicle speed sensor O-ring for cuts, tears or REMOVAL
general deterioration. Replace as necessary.
1. Proceed as follows:
2. Insert the sensor into the transmission case and install
FLHT/C/U: Remove the outer fairing. See Section 2.29
the bolt. Tighten the bolt to 84-108 in-lbs (9-12 Nm).
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
3. Feed cable rearward under and inboard of the chrome FAIRING/WINDSHIELD, REMOVAL.
starter cover. Running cable up the frame downtube, FLTR: Remove instrument bezel. See Section 2.30
capture cable in new cable strap anchored in hole of UPPER FAIRING/WINDSHIELD (FLTR), BEZEL,
frame downtube. REMOVAL, steps 1-2. Raising bezel slightly, remove
NOTE anchor on ambient temperature sensor from bottom
inboard ear of speedometer bracket.
Anchored cable strap also captures the main harness and
2. Bend back the external latches slightly and remove
neutral switch conduit.
speedometer connector [39], 12-place Packard, at back
4. Draw cable rearward between frame downtube and side of speedometer.
of battery box to area of electrical bracket. 3. Remove two allen head socket screws to free speedom-
eter bracket from back of speedometer gauge. On FLHT/
5. Referencing the following table, install terminals into pin
C/U models, leave anchors on interconnect harness
housing of 3-place Deutsch.
installed in outboard ears of speedometer bracket.

Table 8-13. Vehicle Speed Sensor [65] 4. Push speedometer gauge toward rear of motorcycle to
remove from inner fairing (FLHT/C/U) or bezel bore
Wire Color Chamber Number (FLTR).

Red A
White B INSTALLATION
Black C
1. Insert speedometer gauge into inner fairing (FLHT/C/U)
or bezel bore (FLTR).
NOTE
2. Align holes in speedometer bracket with those at back of
For instructions on properly installing wire terminals, see speedometer gauge and start two allen head socket
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS, screws.
REMOVING/INSTALLING PINS.
3. Rotate speedometer gauge until tabs at top and bottom
6. Mate pin and socket halves of vehicle speed sensor con- of bracket engage slots in inner fairing (FLHT/C/U) or
nector. Route connector and cable on inboard side of bezel (FLTR).
electrical bracket as shown in Figure 8-112. Be sure that
NOTE
cable is properly routed or wires may be pinched during
installation of bracket. On FLHT/C/U models, both the speedometer and tachome-
ter brackets are oriented with the ears on the outboard side.
7. Slide electrical bracket onto studs at side of battery box. On FLTR models, the brackets are oriented with the ears
inboard.
8. Install flange nuts on studs and tighten to 36-48 in-lbs
(4.1-5.4 Nm). 4. Verify that gauge is properly aligned and tighten two
9. Align barbed studs in side cover with grommets in frame allen head socket screws to 10-20 in-lbs (1.1-2.3 Nm).
downtubes and push firmly into place (no tools 5. Install speedometer connector [39], 12-place Packard, at
required). back of speedometer.

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4. Release four paddles to free indicator bulb housing from
f2254x8x
lense assembly. See Figure 8-115. Remove lense
assembly from inner fairing (FLHT/C/U) or bezel (FLTR),
if damaged.
5. To replace indicator lamp bulbs, carefully remove rubber
boot from bulb housing. Remove bulb from socket in
boot.

INSTALLATION
1. Install new bulb in socket. Install boot in bulb housing.
2. Place lense assembly in inner fairing (FLHT/C/U) or
bezel (FLTR), if removed. Note position of oil icon to be
sure that lense is right side up.
3. Engage all four paddles on lense assembly with tabs on
indicator bulb housing. Be sure that flange on bulb hous-
Figure 8-114. Anchor Interconnect Harness in Lower ing faces upward.
Ears of Speedometer/Tachometer Brackets
4. Mate pin and socket halves of indicator lamps connector
[21], 10-place Multilock.
6. Proceed as follows: 5. On FLHT/C/U models, install tachometer gauge. See
FLHT/C/U: Verify that anchors on interconnect harness GAUGES- 4 INCH DIAMETER, TACHOMETER,
are installed in lower outboard ears of both the speed- INSTALLATION, in this section.
ometer and tachometer brackets. See Figure 8-114. 6. Proceed as follows:
Install outer fairing. See Section 2.29 UPPER FAIRING/
WINDSHIELD (FLHT/C/U), OUTER FAIRING/WIND- FLHT/C/U: Install outer fairing. See Section 2.29
SHIELD, INSTALLATION. UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FLTR: Install anchor on ambient temperature sensor into FAIRING/WINDSHIELD, INSTALLATION.
bottom inboard ear of speedometer bracket. Install FLTR: Install instrument bezel. See Section 2.30
instrument bezel. See Section 2.30 UPPER FAIRING/ UPPER FAIRING/WINDSHIELD (FLTR), BEZEL,
WINDSHIELD (FLTR), BEZEL, INSTALLATION, steps INSTALLATION, steps 1-2.
3-5.

Indicator Lamp
INDICATOR LAMPS Connector [21]
10-Place Multilock

REMOVAL
Bulb
1. Proceed as follows:
Housing
FLHT/C/U: Remove the outer fairing. See Section 2.29
UPPER FAIRING/WINDSHIELD (FLHT/C/U), OUTER
FAIRING/WINDSHIELD, REMOVAL.
FLTR: Remove instrument bezel. See Section 2.30
UPPER FAIRING/WINDSHIELD (FLTR), BEZEL,
N Rubber
REMOVAL, steps 1-2.
Boot
2. Disconnect indicator lamps connector [21], 10-place
Multilock. Depress button on plug side of connector and
Paddle
pull apart pin and socket halves. Lense
f2262x8x
3. On FLHT/C/U models, remove tachometer gauge to
access indicator lamp assembly. See GAUGES- 4 INCH
DIAMETER, TACHOMETER, REMOVAL, in this section. Figure 8-115. Indicator Lamp Assembly

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GAUGES/INSTRUMENTS (FLHR/C/S) 8.28

FUEL GAUGE

REMOVAL
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. At bottom left side of fuel tank, gently pull on convoluted
tubing to draw fuel gauge connector [117], 4-place Mul-
tilock, out of tunnel. Depress button on socket terminal
side and pull apart pin and socket halves.
3. Remove terminals from pin housing.

NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC-
TORS, REMOVING SOCKET/PIN TERMINALS.

4. Remove convoluted tubing from wires.

5. Remove the gauge cap on the top left side of the fuel f2155x8x

tank. Do not twist the cap during removal. Hold the cap
firmly and pull upward just far enough to free the cap
from the fuel tank.
6. To remove fuel gauge from vehicle, feed wires and pin Convoluted
terminals up into drain tube of fuel tank while carefully Tubing
raising cap.
7. If reusing gauge, inspect rubber seal for tears, cuts or
general deterioration. Replace seal if necessary. Install
new seal so that flat side contacts edge of gauge.

INSTALLATION 8870

1. Place new fuel gauge assembly next to discarded unit

and cut wires to proper length. Figure 8-116. Fuel Gauge (FLHR/C/S)

2. Crimp new pin terminals onto fuel gauge wires.

NOTE 5. Install terminals into pin housing of 4-place Multilock.

For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS, Table 8-14. Fuel Gauge [117]
CRIMPING INSTRUCTIONS.
Wire Color Chamber
3. While carefully lowering cap, feed wires down into drain
Fuel Injected Carbureted Number
tube until pin terminals exit hole at bottom of fuel tank.
Gently pull wires (to remove slack) while installing the
Orange Orange 1
fuel gauge cap on the fuel tank. Do not twist the cap dur-
ing installation. Hold the cap firmly and press downward Yellow/White - 2
until it snaps in place. - - 3
4. Install convoluted tubing on wires. Black Black 4

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NOTE
For instructions on properly installing wire terminals, see 1WARNING
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNEC- To protect against shock and accidental start-up of vehi-
TORS, INSTALLING SOCKET/PIN TERMINALS. cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
6. Route pin housing and convoluted tubing forward and
death or serious injury.
then inboard between front of crossover hose fitting and
bottom of fuel tank. Mate pin and socket halves of fuel 2. Unthread bolt and remove battery negative cable (black)
gauge connector [117], 4-place Multilock. Feed connec- from battery negative (-) terminal.
tor into tunnel of fuel tank. See lower frame of Figure 8- 3. Carefully cut anchored cable strap securing main har-
116. ness bundle, instrument console conduit, and fuel vapor
7. Install maxi-fuse. See Section 8.3 SYSTEM FUSES, vent tube to left side of frame backbone.
MAXI-FUSE, INSTALLATION. 4. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRS models).
5. On FLHRS models only, remove bolt (with flat washer) to
free rear of fuel tank from frame backbone. Removal of
VEHICLE SPEED SENSOR rear bolt also releases instrument console bracket.
6. Lay a clean shop towel on forward part of rear fender.
See Section 8.27 GAUGES/INSTRUMENTS (FLHT/C/U,
7. Raise instrument console and bend back flexible clamp
FLTR), VEHICLE SPEED SENSOR.
on canopy to release main harness conduit. Depress
button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
8. Lay instrument console upside down on shop towel.
SPEEDOMETER 9. If necessary, bend back the flexible metal clips to free
the main harness conduit from the bottom of the con-
sole.
REMOVAL 10. Bend back the external latches slightly and remove
speedometer connector [39], 12-place Packard, at back
1. Remove seat. See Section 2.24 SEAT, REMOVAL. of speedometer.

f2095x8x
Latch Reset Ignition/Light
(1 of 3) Switch Indicator Lights Key Switch Connector [33]
Assembly
Flexible Flexible
Clip Clip
Lock
Ring

Speedometer
Connector [39]

Plastic
Speedometer Indicator Lights Flexible Clip
Connector [21] Clip

Figure 8-117. Instrument Console Assembly (FLHR/C)

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11. See Figure 8-117. Gently pry the three latches upward INDICATOR LIGHTS
to release the lock ring from the back of the speedome-
ter.
12. Turn the console over and remove the speedometer NOTE
from the top side. All FLHR/C/S models are equipped with Light Emitting
Diodes (LED’s) in lieu of indicator lamps. The indicator light
13. Remove gasket from console speedometer bore.
assembly is not serviceable. If one LED is bad, the indicator
light assembly must be replaced.

INSTALLATION
REMOVAL
1. Lubricate the groove in the rubber speedometer gasket
with isopropyl alcohol or glass cleaner. Place the gasket 1. Remove seat. See Section 2.24 SEAT, REMOVAL.
into position around the console speedometer bore.
2. From the top side of the console, feed the speedometer 1WARNING
into the gasket. Lubricate the gasket with isopropyl alco-
hol or glass cleaner, if necessary. The speedometer To protect against shock and accidental start-up of vehi-
should fit snugly against the gasket without movement. cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
3. Turn the console over. Place the lock ring over the back death or serious injury.
of the speedometer aligning the two slots with the con-
sole bosses. Press the latches down until they lock into 2. Unthread bolt and remove battery negative cable (black)
position. from battery negative (-) terminal.
4. Install speedometer connector [39], 12-place Packard, at 3. Carefully cut anchored cable strap securing main har-
back of speedometer. ness bundle, instrument console conduit, and fuel vapor
5. If released, position the speedometer harness so that it vent tube to left side of frame backbone.
runs the length of the console on the left side. Bend the 4. Remove acorn nut from instrument console. If present,
flexible metal clip to capture the harness conduit. See also remove Phillips screw and large flat washer (absent
Figure 8-117. on FLHRS models).
6. Slide head of console mounting bolt into slot at top of 5. On FLHRS models only, remove bolt (with flat washer) to
canopy, if removed. free rear of fuel tank from frame backbone. Removal of
7. Moving instrument console toward installed position, rear bolt also releases instrument console bracket.
install fuel level sender connector [141], 3-place Mini- 6. Lay a clean shop towel on forward part of rear fender.
Deutsch, at top of canopy. Bend flexible clamp to capture
main harness conduit. 7. Raise instrument console and bend back flexible clamp
on canopy to release main harness conduit. Depress
8. Align hole in instrument console with console mounting button on socket side and remove fuel level sender/fuel
bolt and place into position on fuel tank. pump connector [141], 3-place Mini-Deutsch.
9. Install acorn nut at top of instrument console and tighten 8. Lay instrument console upside down on shop towel.
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRS 9. Disconnect the indicator lights connector [21], 8-place
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm). Mini-Deutsch, at back of console. Depress the external
latches and use a rocking motion to separate pin and
10. On FLHRS models only, install bolt (with flat washer) to socket halves.
secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 10. Remove indicator lights assembly from console as fol-
Nm). lows:

11. Snap anchor of new cable strap into hole on left side of a. Insert the blade of a large screwdriver under rear
frame backbone. Tighten cable strap capturing main har- corner of indicator lights assembly.
ness bundle, instrument console conduit, and fuel vapor
b. Using thumb and index finger, squeeze front and
vent tube. Cut any excess cable strap material.
rear paddles on same side of assembly while rotat-
12. Insert bolt through battery negative cable (black) into ing screwdriver. See Figure 8-118.
threaded hole of battery negative (-) terminal. Tighten
c. When one side of assembly becomes free, repeat
bolt to 60-96 in-lbs (6.8-10.9 Nm).
procedure on opposite side to release unit from
13. Install seat. See Section 2.24 SEAT, INSTALLATION. console.

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6. Install acorn nut at top of instrument console and tighten
f2095x8x
Paddles to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRS
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

7. On FLHRS models only, install bolt (with flat washer) to

secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
Nm).

8. Snap anchor of new cable strap into hole on left side of

frame backbone. Tighten cable strap capturing main har-
ness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material.

9. 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).

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

IGNITION SWITCH
Figure 8-118. Release Paddles to Free
Indicator Lights Assembly (FLHR/C)
NOTE

See Section 8.18 IGNITION/LIGHT KEY SWITCH AND

INSTALLATION FORK LOCK, FLHR/C/S.

1. Install indicator lights assembly into console as follows:

a. Place assembly into position in console engaging
four paddles in slots of indicator light assembly.
b. While pushing down on assembly with thumbs,
push up on lense on outboard side of console until
assembly fits snugly.

2. Connect the indicator lights connector [21], 8-place Mini-

Deutsch, at back of console. Align tabs on socket hous-
ing with grooves on pin housing, and push connector
halves together until the latches “click.”
3. Slide head of console mounting bolt into slot at top of
canopy, if removed.
4. Moving instrument console toward installed position,
install fuel level sender connector [141], 3-place Mini-
Deutsch, at top of canopy. Bend flexible clamp to capture
main harness conduit.
5. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.

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FUEL LEVEL SENDER (CARBURETED) 8.29

FLHT/C CANOPY 13. Remove and discard canopy gasket. Verify that sealing
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
NOTE 14. Replace fuel level sender. See FUEL LEVEL SENDER
For replacement of the fuel level sender on fuel injected mod- in this section.
els, see Section 9.4 FUEL TANK (FUEL INJECTED), FUEL
LEVEL SENDER.
INSTALLATION
1. Obtain new canopy gasket. With the locator bump on the
REMOVAL gasket OD toward the front, position gasket at bottom of
1. Remove seat. See Section 2.24 SEAT, REMOVAL. canopy. Start four nubs on gasket into holes in canopy.
Moving to top of canopy, alternately grasp each nub and
pull through hole.
1WARNING
To protect against shock and accidental start-up of vehi- CAUTION
cle, disconnect the negative battery cable before pro-
Exercise care to avoid bending float rod of fuel level
ceeding. Inadequate safety precautions could result in
sender during installation. A bent float rod will result in
death or serious injury.
erroneous gauge readings.
2. Unthread bolt and remove battery negative cable (black) 2. Holding assembly so that canopy is at a 45˚ angle to top
from battery negative (-) terminal. of fuel tank, insert assembly into left side lobe of fuel
3. Drain the fuel tank. See Section 4.6 VACUUM OPER- tank.
ATED FUEL VALVE (CARBURETED), DRAINING FUEL
TANK, steps 1-8.
4. Carefully cut anchored cable strap securing main har-
ness bundle, fuel level sender conduit, and fuel vapor Sealing
Device
vent tube to left side of frame backbone.
5. 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.
6. Remove Allen head screw to detach flange at rear of
f1963x9x
console from clip nut on fuel tank weldment.
7. Lay a clean shop towel on forward part of rear fender. Figure 8-119. Canopy Sealing Screws
8. Remove filler cap from neck of fuel tank. Remove con-
sole and lay upside down on shop towel. Reinstall filler 1
cap.
7 9
9. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
3 6
filler neck.
10. Depress button on socket side and remove fuel level
sender connector [141], 3-place Mini-Deutsch, at top of 5 4
canopy.
11. Using a T20 TORX bit, remove ten screws around the
outer edge of the canopy. Discard screws. 10 8
12. Remove canopy with attached fuel level sender from fuel
tank. Tilt canopy toward the right until it is at a 45˚ angle f2011x9x 2
to top of fuel tank and then carefully pull assembly from
left side lobe of fuel tank. Figure 8-120. Canopy Torque Sequence (FLHR)

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1WARNING
Always use new screws when installing the canopy. Fuel
Reusing old screws may compromise sealing integrity Tank
resulting in gas leaks. Gas leakage can cause fire or Console
explosion which could result in death or serious injury.

NOTE
Check canopy screws for proper sealing devices. Screws Fuel Level
must have a bonded seal on underside of head. Replace Sender
screws if seal is missing or damaged. See Figure 8-119. Conduit

3. While pushing down on the canopy, align holes in can-

opy with those in fuel tank. Hand start ten new T20
Fuel
TORX screws in perimeter of canopy. Tighten screws to
Overflow
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in Fuel Vapor Hose
Figure 8-120. Vent Tube
(To Vapor Valve)
4. Connect fuel vapor vent tube to fitting on filler neck of
fuel tank.
Main
5. Install fuel level sender connector [141], 3-place Mini- Harness
Deutsch, at top of canopy. Bundle
Anchored Main
6. Remove filler cap. Position console on canopy. Route Cable Strap Harness
cables from beneath console as shown in Figure 8-121. Bundle
f1739b9x
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
Figure 8-121. Console Cable/Hose Routing
7. Install Allen head screw to fasten rear flange of console - FLHT/C, FLTR (Top View)
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
8. Open fuel door on console. Install two Allen head screws REMOVAL
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm). 1. Drain the fuel tank. See Section 4.6 VACUUM OPER-
ATED FUEL VALVE (CARBURETED), DRAINING FUEL
9. Snap anchor of new cable strap into hole on left side of
TANK, steps 1-8.
frame backbone. Tighten cable strap capturing main har-
ness bundles, fuel level sender conduit, and fuel vapor 2. Remove seat. See Section 2.24 SEAT, REMOVAL.
vent tube. See Figure 8-121. Cut excess cable strap
material.
10. Insert bolt through battery negative cable (black) into
1WARNING
threaded hole of battery negative (-) terminal. Tighten To protect against shock and accidental start-up of vehi-
bolt to 60-96 in-lbs (6.8-10.9 Nm). cle, disconnect the negative battery cable before pro-
11. Install seat. See Section 2.24 SEAT, INSTALLATION. ceeding. Inadequate safety precautions could result in
death or serious injury.
12. Turn the handle of the fuel valve to OFF and fill the fuel
tank. Carefully inspect for leaks. Turn the valve handle to 3. Unthread bolt and remove battery negative cable (black)
ON and start engine. Repeat inspection. from battery negative (-) terminal.
13. Stop engine and return the valve to the OFF position. 4. Carefully cut anchored cable strap securing main har-
ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
FLHR/S CANOPY 5. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRS models).
NOTE
For replacement of the fuel level sender on fuel injected mod- 6. On FLHRS models only, remove bolt (with flat washer) to
els, see Section 9.4 FUEL TANK (FUEL INJECTED), FUEL free rear of fuel tank from frame backbone. Removal of
LEVEL SENDER. rear bolt also releases instrument console bracket.

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7. Raise instrument console and bend back flexible clamp NOTE

on canopy to release main harness conduit. Depress Check canopy screws for proper sealing devices. Screws
button on socket side and remove fuel level sender con- must have a bonded seal on underside of head. Replace
nector [141], 3-place Mini-Deutsch. screws if seal is missing or damaged. See Figure 8-119.
3. While pushing down on the canopy, align holes in can-
CAUTION opy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
When removing instrument console, exercise caution to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
avoid damaging speedometer unit. Wrap console in a
Figure 8-120.
clean, dry shop towel to prevent damage.
4. Connect fuel vapor vent tube to fitting at top of canopy.
8. Secure instrument console to top of rear fender using
bungee cords. 5. Slide head of console mounting bolt into slot at top of
canopy, if removed.
9. Remove console mounting bolt from slot at top of can-
6. Moving instrument console toward installed position,
opy.
install fuel level sender connector [141], 3-place Mini-
10. Gently pry fuel vapor vent tube from fitting at top of can- Deutsch, at top of canopy. Bend flexible clamp to capture
opy. main harness conduit.
11. Using a T20 TORX bit, remove ten screws around the 7. Align hole in instrument console with console mounting
outer edge of the canopy. Discard screws. bolt and place into position on fuel tank.
12. Remove canopy with attached fuel level sender from fuel 8. Install acorn nut at top of instrument console and tighten
tank. Tilt canopy toward the right until it is at a 45˚ angle to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
to top of fuel tank and then carefully pull assembly from Phillips screw and large flat washer (absent on FLHRS
left side lobe of fuel tank. models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
13. Remove and discard canopy gasket. Verify that sealing 9. On FLHRS models only, install bolt (with flat washer) to
devices from screws are not lodged in canopy holes. secure rear of fuel tank and instrument console bracket
Remove and discard devices if present. to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
Nm).
14. Replace fuel level sender. See FUEL LEVEL SENDER
on this page. 10. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
ness bundle, instrument console conduit, and fuel vapor
INSTALLATION vent tube. Cut any excess cable strap material.
11. Insert bolt through battery negative cable (black) into
1. Obtain new canopy gasket. With the locator bump on the threaded hole of battery negative (-) terminal. Tighten
gasket OD toward the front, position gasket at bottom of bolt to 60-96 in-lbs (6.8-10.9 Nm).
canopy. Start four nubs on gasket into holes in canopy.
Moving to top of canopy, alternately grasp each nub and 12. Install seat. See Section 2.24 SEAT, INSTALLATION.
pull through hole. 13. Turn the handle of the fuel valve to OFF and fill the fuel
tank. Carefully inspect for leaks. Turn the valve handle to
ON and start engine. Repeat inspection.
CAUTION
14. Stop engine and return the valve to the OFF position.
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will FUEL LEVEL SENDER
result in erroneous gauge readings.

2. Holding assembly so that canopy is at a 45˚ angle to top REMOVAL

of fuel tank, insert assembly into left side lobe of fuel
tank keeping the float rod positioned to the right of the
fuel gauge drain tube. CAUTION

Do not replace the special teflon coated fuel level sender

1WARNING wiring with ordinary bulk wire. Ordinary insulation mate-
rials may deteriorate when in contact with gasoline.
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity NOTE
resulting in gas leaks. Gas leakage can cause fire or Damaged fuel level sender wiring requires replacement of
explosion which could result in death or serious injury. the fuel level sender unit.

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1. See FLHT/C CANOPY, REMOVAL, or FLHR/S CAN-

OPY, REMOVAL, in this section. f2060x8x

2. Cut cable strap to release wiring from support arm.

3. Unwind spiral tubing from fuel level sender wiring.
4. At bottom of canopy, remove socket terminal from spade Push
contact on connector clip.

Pull
1CAUTION
Always wear proper eye protection when drilling. Flying
debris may result in eye injury.

CAUTION

Exercise care to avoid bending support arm during

removal of the fuel level sender. Support area around
rivet head when drilling or tapping. A bent support arm
will result in erroneous gauge readings.
To disengage tabs from windows, simultaneously
5. Drill off head of fuel level sender rivet using a 1/4 inch pull on one safety pin while pushing on the other.
drill bit. Exercise caution to avoid enlarging hole in sup-
port arm when drilling. Use a punch to tap rivet shaft
through hole in support arm if necessary. Blow away all Pull terminals from wire block and cut.
metal shavings and debris using compressed air.
6. Remove socket terminals from 3-place Mini-Deutsch
connector on canopy. Proceed as follows:
a. At underside of canopy, take note of the rectangular
opening or window on each side of the connector
body. Now take note of the tab inside each window.
b. Obtain two safety pins. On each side of connector
body, insert a safety pin between body and wire
block until end of each pin appears in window. To
disengage tabs from windows, gently pull on one
safety pin while pushing on the other. See upper
frame of Figure 8-122. With tabs released, gently
tug on wires to release wire block from connector
body.
f2059x8x
c. Pull the wire socket terminals out of the wire block.
See lower frame of Figure 8-122. Cut off the socket Figure 8-122. Remove Wire Block and Cut Terminals
terminals and back the wires out of the wire block.
d. Insert wire block back into connector body until tabs
lock in windows. One corner of wire block and con-
nector body is square to prevent improper installa-
tion. 3. Insert socket terminals into wire block. Take note of the
table below for wire locations.

INSTALLATION Table 8-15. Fuel Level Sender [141]

1. Position new fuel level sender on inboard side of support
arm fitting finger at end of support arm into bottom hole Chamber Wire Color Function
in fuel level sender flange. 1 - -
2. Align top hole in fuel level sender flange with hole in sup- 2 Yellow Sender Output
port arm and install new rivet. Insert rivet through the
support arm first, so that deformed end is on the fuel 3 Black Ground
level sender side.

2004 Touring: Electrical 8-97

HOME

NOTE INSTALLATION
A series of dots are molded into the wire end of the block to
indicate wire location, one dot indicating chamber 1, two dots 1. Apply a very thin film of clean H-D 20W50 engine oil to
chamber 2, three dots chamber 3. (Wire location numbers new O-ring. Install O-ring in groove of connector body.
are also stamped below the terminals inside the Mini-Deutch
2. Fit connector body into hole at top of canopy. At under-
pin housing.)
side of canopy, install connector clip engaging slots in
4. Gently tug on wires to verify that they will not back out of connector body.
wire block. 3. Insert wire block back into connector body until tabs lock
5. Install socket terminal onto spade contact on connector in windows. One corner of wire block and connector
clip. body is square to prevent improper installation.

6. Wind spiral tubing around fuel level sender wiring. 4. Install socket terminal onto spade contact on connector
clip.
7. Insert new cable strap into hole in support arm. Tighten
cable strap capturing fuel level sender wiring. Cut any 5. See FLHT/C CANOPY, INSTALLATION, or FLHR/S
excess cable strap material. CANOPY, INSTALLATION, in this section.
8. See FLHT/C CANOPY, INSTALLATION, or FLHR/S
CANOPY, INSTALLATION, in this section.

CANOPY CONNECTOR/O-RING

REMOVAL
1. See FLHT/C CANOPY, REMOVAL, or FLHR/S CAN-
OPY, REMOVAL, in this section.
2. At bottom of canopy, remove socket terminal from spade
contact on connector clip.
3. Remove wire block from connector body as described
under FUEL LEVEL SENDER, REMOVAL, steps 6(a)-
6(b), on the previous page.
4. Slide connector clip from slots on connector body.
Remove connector body from canopy.
5. Remove O-ring from groove on connector body.

8-98 2004 Touring: Electrical