Professional Documents
Culture Documents
SPECIFICATIONS
8.1
IGNITION TIMING
ALL FL Models
RANGE
Starter
Relay
FLHR/C
Instruments
TDC - 50 BTDC
START
Brake Light
Relay
Security
System
TDC
4-Way Flasher
Spare
Fuses
Brakes/
Cruise
ALTERNATOR SYSTEM
Output Voltage @ 3600 rpm14.3-14.7
FLHR, FLHRI, FLHRCI, FLHT, FLHTC, FLTR
Headlamp
Amperes 38 amp
P&A
f2022x8x
Accessory
Lighting
BATTERY
Ignition
FLTR, FLHT/C/U
Voltage 12V
Radio
Radio Memory
Power
Instruments
Brake Light
Relay
Security
System
4-Way Flasher
FUSES
Circuit
Main
Spare
Fuses
Brakes/
Cruise
Rating
(Amperes)
Color
Terminal
Type
40
Threaded
Posts
Headlamp
P&A
System Fuses
Accessory
Radio Power
10
Red
Blade
Brakes/Cruise
15
Blue
Blade
P&A
10
Red
Blade
Radio Memory
15
Blue
Blade
Security System
(Hazard 4-Way Flasher)
15
Blue
Blade
Accessory
15
Blue
Blade
Instruments
15
Blue
Blade
Ignition
15
Blue
Blade
Lighting
15
Blue
Blade
Headlamp
15
Blue
Blade
Fuel Pump
15
Blue
Blade
ECM Power
15
Blue
Blade
f2023x9x
Lighting
Ignition
ECM Power
f1918x9x
EFI Fuses
8-1
HOME
SPARK PLUG
ft/in-lbs
Nm
36-60 in-lbs
4.1-6.8 Nm
20-30 in-lbs
2.3-3.4 Nm
25-35 in-lbs
2.8-4.0 Nm
Handlebar clamp to
master cylinder housing
screws
60-80 in-lbs
6.8-9.0 Nm
35-45 in-lbs
4-5 Nm
Handlebar clamp to
clutch lever bracket TORX
screws
60-80 in-lbs
6.8-9.0 Nm
Item
No.
Part No.
32317-86A
6R12
Size
Gap
12 mm
0.038-0.043 in.
0.97-1.09 mm
NOTE
Be sure spark plugs are gapped to specification before installation.
TORQUE VALUES
Item
Ignition module socket
head screws
ft/in-lbs
Nm
50-60 in-lbs
5.7-6.8 Nm
Neutral switch
120-180 in-lbs
13.6-20.3 Nm
80-100 in-lbs
9.0-11.3 Nm
80-100 in-lbs
9.0-11.3 Nm
10-20 in-lbs
1.1-2.3 Nm
Tachometer bracket
socket screws
10-20 in-lbs
1.1-2.3 Nm
25-35 in-lbs
2.8-4.0 Nm
84-144 in-lbs
9.5-16.3 Nm
Spark plug
12-18 ft-lbs
16-24 Nm
55-75 in-lbs
6.2-8.5 Nm
60-96 in-lbs
6.8-10.9 Nm
70-100 in-lbs
7.9-11.3 Nm
84-108 in-lbs
9-12 Nm
Speedometer speed
sensor screw
20-35 in-lbs
2.3-4.0 Nm
10-20 in-lbs
1.1-2.3 Nm
Speedometer bracket
socket screws
15-20 ft-lbs
20-27 Nm
5.7-10.2 Nm
9-18 in-lbs
1.0-2.0 Nm
50-90 in-lbs
15-20 ft-lbs
20-27 Nm
6-11 in-lbs
0.7-1.2 Nm
72-108 in-lbs
8.1-12.2 Nm
18-24 in-lbs
2.0-2.7 Nm
20-24 in-lbs
2.3-2.7 Nm
60-96 in-lbs
6.8-10.9 Nm
35-45 in-lbs
4.0-5.1 Nm
22-28 in-lbs
2.5-3.2 Nm
40-48 in-lbs
4.5-5.4 Nm
20-25 in-lbs
2.3-2.8 Nm
20-25 in-lbs
2.3 - 2.8 Nm
4.0-5.7 Nm
1.1-1.7 Nm
35-50 in-lbs
10-15 in-lbs
1.0-2.0 Nm
4.1-6.8 Nm
9-18 in-lbs
36-60 in-lbs
25-30 in-lbs
2.8-3.4 Nm
Ignition switch
head screws
button
18-23 in-lbs
2.0-2.6 Nm
Ignition switch
nut
DOM
50-70 in-lbs
5.7-7.9 Nm
125-150 in-lbs
14.1-16.9 Nm
HDI
Continued ...
8-2
HOME
BULB CHART
Lamp Description,
All Lamps 12V
HEADLAMP
FLHT/C/U, FLHR/C
FLTR
POSITION LAMP (HDI)
PASSING LAMPS
(DOM)
(HDI)
TAIL AND STOP LAMP
Tail Lamp
Stop Lamp
Tail Lamp (HDI)
Stop Lamp(HDI)
License Plate (HDI)
TURN SIGNAL LAMP
Front/Running
Front (HDI)
Rear
Rear (HDI)
TOUR-PAK
Side Marker Lamps *
Tail/Brake Lamps (Ultra)
FENDER TIP LAMPS *
INSTRUMENT PANEL LAMPS
FLHT/C/U, FLTR
High Beam
Oil Pressure
Neutral
Turn Signal
GAUGE LAMPS
FLHT/C/U, FLTR
Speedometer **
Tachometer **
Voltmeter
Oil Pressure Gauge
Air Temperature Gauge
Fuel Gauge
Engine **
8.2
Number of
Current Draw
Bulbs Required (Amperage)
Wattage
Harley-Davidson
Part No.
1
2
1
4.58/5
4.58/5
.32
55/60
55/60
3.9
68329-03
68329-03
53438-92
2
2
1
30
35
7/6
27/24
5/6
21/24
5.2
68674-69
68847-98
Early/Late***
68168-89A/68167-88
2.50
2.92
Early/Late***
0.59/0.59
2.25/2.10
0.42/0.59
1.75/2.10
0.37
2
2
2
2
2.25/.59
1.75
2.25
1.75
27/7
21
27
21
68168-89
68163-84
68572-64B
68163-84
4
2
2
0.3
0.59
0.3
3.7
7
3.7
53439-79
68168-89A
53439-79
1
1
1
2
0.15
0.15
0.15
0.15
2.1
2.1
2.1
2.1
68024-94
68024-94
68024-94
68024-94
1
1
1
1
0.24
0.24
0.24
0.24
3.4
3.4
3.4
3.4
67445-00
67445-00
67445-00
67445-00
68169-90A/68167-88
53436-97
INSTRUMENT PANEL/
GAUGE LAMPS
FLHR/C
High Beam **
Oil Pressure **
Neutral **
Turn Signal **
Fuel Gauge **
Speedometer **
Odometer **
Engine **
8-3
HOME
NOTES
8-4
HOME
IGNITION MODULE
8.3
REMOVAL
1.
2.
3.
4.
Ignition
Module
f1968x9x
INSTALLATION
1.
2.
3.
Connector [11]
Connector [10]
Gray
Black
4.
8-5
HOME
ENGINE SENSORS
8.4
MANIFOLD ABSOLUTE
PRESSURE SENSOR
MAP Sensor
T20 TORX
Screw
Removal
1.
2.
3.
4.
5.
Installation
1.
2.
Retaining
Clip
Figure 8-3. Intake Manifold
3.
Install T20 TORX screw and tighten to 25-35 in-lbs (2.84.0 Nm). See Figure 8-3.
4.
5.
Install fuel tank. See Section 4.7 FUEL TANK (CARBURETED), INSTALLATION (AFTER PARTIAL REMOVAL),
FLHT/C, FLTR, or FLHR.
8-6
HOME
IGNITION COIL
REMOVAL
1.
2.
3.
4.
5.
8.5
6.
8316
INSTALLATION
1.
2.
3.
4.
Install spark plug cable to front cylinder onto left side coil
tower. Verify that spark plug cable is captured in doublesided cable clip at bottom left side of frame backbone.
Install new cable clip on T-stud if damaged or missing.
See Figure 8-7.
5.
f1925x8x
Front
Rear
Figure 8-5. Install Bracket to Ignition Coil
8-7
HOME
8.6
SPARK PLUGS
Inspect spark plugs at 5000 miles (8,000 km) and replace at
10,000 miles (16,000 km).
The number 6R12 plug is supplied as original equipment and
is the only plug that should be used. The resistor plug
reduces radio interference created by the ignition system and
will not adversely affect performance or fuel economy.
REMOVAL
1.
2.
INSPECTION
See Figure 8-6. Examine plugs as soon as they have been
removed. The deposits on the plug base are an indication of
the plug efficiency and are a guide to the general condition of
rings, valves, carburetor and ignition system.
a.
b.
c.
d.
A wet black and shiny deposit on plug base, electrodes and ceramic insulator tip indicate an oil
fouled plug. The condition may be caused by worn
rings and pistons, loose valves or seals, weak battery or faulty ignition.
A dry fluffy or sooty black deposit indicates a too
rich carburetor air-fuel mixture or long periods of
engine idling. Excessive use of the enrichener may
also cause this condition.
An overheated plug can be identified by a light
brown, glassy deposit. This condition may be
accompanied by cracks in the insulator or by erosion of the electrodes. This condition is caused by
too lean an air-fuel mixture, a hot running engine,
valves not seating or improper ignition timing. The
glassy deposit on the spark plug is a conductor
when hot and may cause high speed misfiring. A
plug with eroded electrodes, heavy deposits or a
cracked insulator should be replaced.
A plug with white, yellow or light tan to rusty brown
powdery deposit indicates balanced combustion.
The deposits may be cleaned off at regular intervals
if desired.
CLEANING
1.
8-8
2.
3.
ADJUSTMENT
Use only a wire-type gauge. Bend the outside electrode so
only a slight drag on the gauge is felt when passing it
between electrodes. Never make adjustments by bending the
center electrode. Set gap on all plugs at 0.038-0.043 in.
(0.97-1.09 mm).
INSTALLATION
1.
2.
HOME
3.
4.
INSPECTION
1.
2.
Resistor-type high-tension cables have a carbon-impregnated fabric core (instead of solid wire) for radio noise suppression and improved reliability of electronic components.
Use the exact replacement cable for best results.
Never disconnect a spark plug cable with the engine running. Doing so will result in an electric shock from the
ignition system that could result in death or serious
injury.
1.
Resistance (Ohms)
Front /Rear
5,000 - 11,666
4.
INSTALLATION
1.
2.
Install spark plug cable to front cylinder onto left side coil
tower. Verify that spark plug cable is captured in doublesided cable clip at bottom left side of frame backbone.
Install new cable clip on T-stud if damaged or missing.
See Figure 8-7.
3.
CAUTION
When disconnecting a spark plug cable from the spark
plug terminal, always grasp and pull on the rubber boot
at the end of the cable assembly (as close to the spark
plug terminal as possible). Pulling on the cable portion
will damage the carbon core.
Cable Length
3.
REMOVAL
1WARNING
Position
8327
8-9
HOME
ALTERNATOR/STATOR
8.7
REMOVAL
Rotor
1.
f2120x8x
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
2.
3.
4.
Engine
Sprocket Shaft
1CAUTION
Shaft Protector
Sleeve
b.
c.
Rotate handle of forcing screw in a clockwise direction to remove rotor from shaft.
Thumbscrew
Forcing Screw
b.
8-10
Thumbscrew
Handle
3. Install Rotor Remover/Installer.
Rotate Handle in a Clockwise Direction.
Figure 8-8. Remove Rotor from Engine Sprocket Shaft
HOME
13. Using a T27 TORX drive head, remove four screws to
free stator from crankcase. Discard screws.
14. Using point of awl, carefully lift capped rib on grommet
away from crankcase and then insert into bore between
grommet and casting. See Figure 8-11. Tilt awl slightly
squirting isopropyl alcohol or glass cleaner into opening.
Repeat this step at one or two other locations around
grommet.
15. While pushing on capped rib from outside of crankcase,
draw grommet through bore by pulling on cable stop with
needle nose pliers. Rock grommet back and forth to
facilitate removal, if necessary. Exercise caution to avoid
damaging ribs on grommet if stator is to be reused.
Stator/
Voltage Regulator
Connector [46]
16. Draw stator cables and socket terminals through crankcase bore. For best results, feed one cable and socket
terminal through at a time.
f1910x8x
7.
8.
9.
2.
Clean the rotor using a petroleum solvent. Clean the stator and grommet by wiping it with a clean cloth.
f1912x8x
Cavity
Terminal A
10. Draw connector and cable conduit to rear of engine stabilizer link and then up to area in front of primary chaincase.
11. Depress tangs inside socket housing and back out sockets through wire end of connector. Proceed as follows:
a.
b.
c.
d.
12. Remove conduit from cables. For best results, feed one
cable and socket terminal through conduit at a time.
f1911x8x
Pick
8-11
HOME
Capped
Rib
Stator
f1634x8x
NOTE
The Shaft Protector Sleeve not only protects the threads from
the splines of the rotor, but acts as a guide to ensure that the
rotor is properly centered.
b.
c.
d.
a.
Opening
1CAUTION
INSTALLATION
1.
2.
3.
4.
7.
8.
b.
CAUTION
Do not reuse T27 TORX screws. The threads of the
screws contain a locking compound in pellet form. When
the screw is started, the pellet breaks releasing the compound.
5.
6.
X-Acto Knife
Tang
a.
8-12
HOME
f2119x8x
Rotor
Voltage
Regulator
Flange
Locknut
P-Clamp
Anchored
Cable Clip
Brake Pedal
Weldment
38 AMP
Cable Clip
f2121x8x
Lower
Frame Tube
Rubber
Seal
Secondary
Lock
P-Clamp
Pin
Housing
Socket
Housing
Cable Stop
Grommet
Rotor
Stator
NO
Alternator Rotor Spacer
T27 TORX
Screw
c.
9.
8-13
HOME
CAUTION
Damage to cables can result in electrical problems. Be
sure there is enough clearance with castings to prevent
powertrain movement from chafing cables.
11. Raise voltage regulator as necessary to install left side
leg onto stud. Install locknut and tighten to 70-100 in-lbs
(7.9-11.3 Nm).
12. Tighten right side locknut to 70-100 in-lbs (7.9-11.3
Nm).
13. Mate pin and socket housings of stator/voltage regulator
connector. Push halves together until the latch clicks.
14. At bottom of voltage regulator, slide connector toward
right side of vehicle until groove on connector fully
engages ridge on bracket.
8-14
HOME
VOLTAGE REGULATOR
8.8
REMOVAL
1.
1WARNING
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
2.
3.
4.
Stator/
Voltage Regulator
Connector [46]
f1910x8x
5.
6.
8.
7.
9.
NOTE
For best results, insert blade of small screwdriver into gap at
side of clip and gently rotate end of screwdriver to pop open.
Left
Side
10. Free voltage regulator cable conduit from cable clip on Tstud inboard of rear brake pedal weldment.
Right
Side
Silver Post
13. Remove locknuts from studs on lower frame crossmember. Remove voltage regulator from studs.
14. Remove cable conduit from P-clips. Remove P-clip from
left side stud. Note that right side P-clip is anchored to
leg of voltage regulator.
To Left Side
Ground Post
INSTALLATION
Stator/Voltage Regulator
Connector [46]
Figure 8-14. Voltage Regulator
f1410x8x
1.
8-15
HOME
f1985x8x
3
4
5
1
Legend:
1.
2.
3.
4.
5.
6.
7.
8.
P-Clip
Lower Frame Crossmember
Voltage Regulator
Stator/Voltage Regulator
Connector [46]
Right Frame Down Tube
1st Cable Clip
2nd Cable Clip
Lower Frame Tube
8
Cable
Clip
Battery
Box
Anchored
Cable Strap
3rd
Cable Clip
2nd
Cable Clip
2
3
f1986x8x
8-16
1st
Cable Clip
HOME
40 Amp Main
Circuit Breaker
Silver Post
Left Side
Ground Post
Figure 8-17. Electrical Connections - Upper Frame Cross Member (Under Seat)
2.
Slide P-clip over left side stud on lower frame crossmember. Slide voltage regulator over studs. Properly oriented, P-clips are positioned at rear of studs with the
open sides down.
3.
4.
5.
6.
NOTE
The two rear cable clips also capture the engine sensor harness conduit and rear brake line.
7.
8.
9.
Install three new cable straps at locations shown in illustration at bottom of Figure 8-16. Hole in frame at rear
location requires anchored type cable strap.
CAUTION
1WARNING
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
8-17
HOME
11. Insert bolt through battery positive cable (red) into
threaded hole of battery positive (+) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
12. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
8-18
13. Rotate the hold-down clamp so that the lip (with rubber
pad) rests on the edge of the battery. Using a T40 TORX
drive head, tighten the clamp bolt to 15-20 ft-lbs (20-27
Nm).
14. Load test charging system.
15. Install seat. See Section 2.22 SEAT, INSTALLATION.
HOME
BATTERY
8.9
GENERAL
DE
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8
7
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EY-EE U.S
1WARNING
Warning
Label
RT
PA
.
NO
f1730x8x
VOLTMETER TEST
External -
Internal -
Eyes -
Contents
are Corrosive.
Wear
Safety Glasses.
Contents
are Explosive.
See Table 8-3. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to
verify that it is in a 100% fully charged condition. If the open
circuit (disconnected) voltage reading is below 12.6V, charge
the battery and then recheck the voltage after the battery has
set for one to two hours. If the voltage reading is 12.8V or
above, perform the LOAD TEST described in this section.
Keep
Flames Away.
Read
Instructions.
Keep Away
From Children.
f1733x8x
8-19
HOME
BATTERY CHARGING
Voltage (OCV)
State of Charge
12.8
100%
12.6
75%
12.3
50%
12.0
25%
11.8
0%
Connect the charger leads to the battery; red positive (+) lead to the positive (+) terminal and black
negative () lead to the negative () terminal. If the
battery is still in the vehicle, connect the negative
lead to the chassis ground. Be sure that the ignition
and all electrical accessories are turned off.
SAFETY PRECAUTIONS
1WARNING
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
2.
3.
4.
CHARGING BATTERY
1.
2.
3.
Inspect the battery screws, clamps and cables for breakage, loose connections and corrosion. Clean clamps.
4.
5.
6.
8-20
1WARNING
Always charge the battery in a well ventilated area.
Explosive hydrogen gas escapes from the battery during
charging. Keep open flames, electrical sparks and smoking materials away from the battery at all times. Failure
to do so could result in death or serious injury.
CAUTION
If the battery releases an excessive amount of gas during charging, decrease the charging rate. If the battery
gets hotter than 110F. (43C) during charging, discontinue charging and allow the battery to cool. Overheating
may result in plate distortion, internal shorting, dryout or
other damage.
HOME
State of Charge
3
Amp Charger
6
Amp Charger
10
Amp Charger
20
Amp Charger
Voltage Reading
% of Charge
12.8 V
100%
12.6 V
75%
2.5 hours
1.25 hours
45 minutes
25 minutes
12.3 V
50%
5 hours
2.5 hours
1.5 hours
50 minutes
12.0 V
25%
7.5 hours
3.75 hours
2.25 hours
70 minutes
11.8 V
0%
10 hours
5 hours
3 hours
1.5 hours
TOURING
28
The figures listed above assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter
charging time. If colder, use a slightly longer charging time.
The use of constant current chargers to charge sealed maintenance-free batteries is not recommended. Any overcharge will cause dryout and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed above and
do not continue charging the battery if it gets hot. When charging, never exceed 15 volts for more than 30 minutes.
1.
NOTE
If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical accessories are turned off.
5.
Remove the battery from the motorcycle. See DISCONNECTION AND REMOVAL in this section. Place the battery on a level surface.
1WARNING
Always unplug or turn OFF the battery charger before
connecting the charger clamps to the battery. Connecting clamps with the charger ON could cause a spark
resulting in a battery explosion. A battery explosion may
rupture the battery case causing a discharge or spray of
sulfuric acid which could result in death or serious
injury.
CAUTION
Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged.
3.
4.
Step away from the battery and turn on the charger. See
the charging instructions in Table 8-4.
1WARNING
Always unplug or turn OFF the battery charger before
disconnecting the charger clamps from the battery. Disconnecting clamps with the charger ON could cause a
spark resulting in a battery explosion. A battery explosion may rupture the battery case causing a discharge
or spray of sulfuric acid which could result in death or
serious injury.
6.
7.
8.
9.
Perform a load test to determine the condition of the battery. See LOAD TEST on this page.
LOAD TEST
The load test measures battery performance under full current load and is the best indicator of battery condition. To
load test the battery, proceed as follows:
8-21
HOME
CAUTION
CAUTION
1.
2.
4.
1WARNING
Always turn the battery load tester OFF before connecting the tester cables to the battery terminals. Connecting
tester cables with the load tester ON could cause a spark
resulting in a battery explosion. A battery explosion may
rupture the battery case causing a discharge or spray of
sulfuric acid which could result in death or serious
injury.
3.
Connect tester leads to battery posts and place induction pickup over negative (black) cable. See Figure 8-20.
Referencing Table 8-4, load battery at 50% of CCA rating using the load tester. Voltage reading after 15 seconds should be 9.6V or more at 70F. (21C).
COLD CRANKING
AMPERAGE (CCA)
100%
50%
TOURING
300
150
1WARNING
Always turn the battery load tester OFF before disconnecting the tester cables from the battery terminals. Disconnecting tester cables with the load tester ON could
cause a spark resulting in a battery explosion. A battery
explosion may rupture the battery case causing a discharge or spray of sulfuric acid which could result in
death or serious injury.
5.
Load
Tester
Install the battery on the motorcycle. See INSTALLATION AND CONNECTION below.
Induction
Pickup
f1731x8x
8-22
Place the fully charged battery into the battery box, terminal side forward.
CAUTION
HOME
1WARNING
f1732x8x
Effect of Temperature on
Battery Self-Discharge Rate
100 %
75 %
CAUTION
50 %
C
A
P
A
C
I
T
Y
at 77F
at 105F
M O N T H S O F S TA N D
1.
2.
3.
Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals.
4.
5.
12
15
STORAGE
1WARNING
Store the battery out of the reach of children. Inadequate
safety precautions could result in death or serious
injury.
CAUTION
The electrolyte in a discharged battery will freeze if
exposed to freezing temperatures. Freezing may crack
the battery case and buckle battery plates.
f2078x8x
Frame
Cross Member
Frame Hole
Cruise Cable
Routing Only
Main Power
To Circuit Breaker
Positive
Battery Cable
Negative
Battery Cable
8-23
HOME
8.10
f1268x2x
REMOVAL
Wider
Ear
1.
Remove the Phillips screw at the bottom of the headlamp door (chrome ring). Remove the headlamp door.
2.
Wire Form
Loop
Hinge
Slots
Backplate
Bulb
Socket
Wire Form
Loop
Lense
INSTALLATION
Figure 8-24. Headlamp Lense/Bulb Assembly
(Rear View)
1.
2.
NOTE
When replacement is required, use only the specified bulb
available from your Harley-Davidson dealer. Improper wattage or bulb may cause charging system problems.
3.
5372
Retaining
Ring Screws
1.
Remove the Phillips screw at the bottom of the headlamp door (chrome ring). Remove the headlamp door.
2.
3.
4.
5.
1WARNING
Figure 8-23. Remove Retaining Ring Screws
(FLHT/C/U Model Shown)
8-24
HOME
f1285b2x
A
25 ft.
(7.62m)
6.
CAUTION
Headlamp
Door
Never touch the quartz bulb with your fingers. Fingerprints will etch the glass and cause premature bulb failure. Always wrap the bulb in paper or a clean dry cloth
during handling.
7.
Slot
NOTE
Wider ear on backplate should point toward the top of the
lense. The top can be determined by the position of the headlamp door bracket, which is at the bottom (on the opposite
side).
8.
9.
5372
Vertical
Adjuster Screw
Horizontal
Adjuster Screw
HEADLAMP ADJUSTMENT
Check headlamp beam for proper height and lateral alignment.
8-25
HOME
1WARNING
DO NOT modify the ignition/light key switch wiring to
disable the automatic-on headlamp feature. High visibility is an important safety consideration for motorcycle
riders. Ensure that the headlamp is on at all times. Failure to do so could result in death or serious injury.
1.
2.
3.
4.
5.
6.
7.
8.
9.
8-26
NOTE
The headlamp adjustment can be performed without removing the headlamp door (chrome ring).
10. If the headlamp alignment requires adjustment, use slots
in headlamp door to insert Phillips screw driver between
headlamp housing and rubber gasket. Turn the vertical
adjuster screw as necessary to adjust the headlamp vertically. Turn the horizontal adjuster screw to adjust the
headlamp horizontally. See Figure 8-26.
HOME
HEADLAMP (FLTR)
8.11
HEADLAMP ASSEMBLY
Bulb
Housing
Plastic
Retainer
REMOVAL
1.
2.
3.
Squeeze two external tabs to disconnect headlamp harness connectors from bulb contacts.
CAUTION
Wrap electrical tape around blade of screwdriver to prevent damage to tabs of transparent lense cover.
4.
5.
From inboard side of outer fairing, release top of transparent lense cover from slots in fairing by gently
depressing two tabs with blade of screwdriver. Depress
two bottom tabs and remove lense cover from fairing.
Depress mounting clips on three hex adjuster studs and
pull headlamp assembly out front of outer fairing. See
Figure 8-27.
Plastic
Boss
Hex Adjuster
Stud
f1546x8x
INSTALLATION
1.
2.
3.
4.
Install the outer fairing. See Section 2.28 UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, INSTALLATION.
REMOVAL
Mounting
Clip
Figure 8-27. Depress Mounting Clips
1.
2.
f1544x8x
8-27
HOME
INSTALLATION
f1545x8x
CAUTION
Never touch the quartz bulb with your fingers. Fingerprints will etch the glass and cause premature bulb failure. Always wrap the bulb in paper or a clean dry cloth
during handling.
Wider
Ear
1.
2.
3.
4.
5.
Install the outer fairing. See Section 2.28 UPPER FAIRING/WINDSHIELD (FLTR), OUTER FAIRING, INSTALLATION.
Slot
Tabs
Figure 8-29. Install New Bulb in Bulb Housing
3.
Squeeze two external tabs to disconnect headlamp harness connector from bulb contacts.
4.
5.
HEADLAMP ADJUSTMENT
Check headlamp beam for proper height and lateral alignment.
1WARNING
The bulb contains Halogen gas under pressure. Wear
adequate eye protection and handle the bulb carefully.
Inadequate safety precautions could result in death or
serious injury.
6.
6421
1WARNING
DO NOT modify the ignition/light key switch wiring to
disable the automatic-on headlamp feature. High visibility is an important safety consideration for motorcycle
riders. Ensure that the headlamp is on at all times. Failure to do so could result in death or serious injury.
6420
Hex Adjuster
Hex Adjuster
LEFT SIDE
RIGHT SIDE
Figure 8-30. Headlamp Adjustment (FLTR)
8-28
HOME
1.
2.
3.
4.
5.
6.
7.
8.
9.
Rotation
CW
Right Only
CCW
Left Only
CCW
Beam
Movement
To the Right
To the Left
Right Only
CW
CW
Upward
CCW
Downward
CW= Clockwise
CCW= Counter-Clockwise
10. Locate the hex adjusters near the bottom edge of the
inner fairing. See Figure 8-30. Turning the adjusters
causes the double headlamp housing to pivot around its
upper mount.
8-29
HOME
PASSING LAMPS
8.12
ADJUSTMENT
8819
1.
2.
3.
NOTE
Passing lamps should shine straight ahead with the center of
the main light beam even with a horizontal line drawn on a
wall 25 feet (7.6 m) away. The line on the wall should be at
the same height as the center of the passing lamps with the
rider mounted.
4.
Nesting Ring
Index Tab
Lamp
Index Tab
Figure 8-32. Install Nesting Ring at Back of
Passing Lamp Bulb
8820
Passing
Lamp
Door
Door
Screw
Mounting
Bracket
1.
2.
3.
INSTALLATION
1.
2.
3.
Install lamp fitting nesting ring over edge of lamp housing. Rotate nesting ring so that nesting ring index tab is
aligned with slot at bottom of lamp housing.
Conduit
Turn Signal
Lamp
Figure 8-31. Passing Lamp and Turn Signal
8-30
HOME
Passing Lamp
Connector [73]
2-Place Multilock (White)
REMOVAL
1.
f2040x8x
Passing Lamp
Connector [73]
2.
3.
5.
Mechanics Wire
f1348c2x
4.
5.
6.
Socket Terminal
f1418x2x
8-31
HOME
NOTE
Be sure that mechanics wire is of sufficient strength to pull
terminals through conduit without breaking. Wire lengths
must also be long enough so that free ends are not lost in
conduit when pulled.
6.
7.
8.
9.
9.
10. Using a T-40 TORX drive head, remove two upper passing lamp bracket bolts from fork. Loosen two lower bolts
and remove bracket from fork.
PASSING LAMP
INSTALLATION
REMOVAL
1.
1.
2.
3.
4.
Using flare nut socket (Snap-on FRX181), tighten locknut to 18 ft-lbs (24.4 Nm).
5.
Reattach mechanics wire to socket terminals and carefully pull ends of mechanics wire to draw socket terminals back through conduit. For best results, pull one wire
at a time.
6.
7.
8-32
See PASSING LAMP BRACKET, REMOVAL, in this section, steps 1-8, but follow instructions for one lamp
instead of two.
INSTALLATION
1.
Lay old passing lamp next to new passing lamp and cut
Gray/Black wire to length.
2.
Strip 3/16 inch (4.8 mm) of insulation off new lamp wire
and crimp on new socket terminal.
NOTE
For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
CRIMPING INSTRUCTIONS.
3.
HOME
8.13
TAIL LAMP
3.
REMOVAL
4.
1.
2.
INSTALLATION
1.
2.
3.
CAUTION
1.
Orient 4-place Multilock socket so that the release button is at the bottom and insert into pin housing until it
clicks. Properly routed, the tail lamp conduit should be
inboard of both the fender tip lamp and left turn signal
lamp conduit as shown in Figure 8-36.
2.
Tail Lamp
Assembly
Chrome Plastic
Bracket
68140-98
f1502b8x
Figure 8-36. Remove Tail Lamp and Depress Button to Release Socket
8-33
HOME
Fender Tip
Lamp [45]
Tail Lamp
[93]
4.
5.
6.
Right Turn
Signal Lamp
[19]
Left Turn
Signal Lamp
[18]
Fender Lights
Harness to
Circuit Board
[94]
INSTALLATION
Opening
1.
2.
3.
4.
f1498x8x
CAUTION
Over tightening screw can crack the plastic bracket or
result in scratching of the fender paint.
Pick
Tool
5.
Pin Housing
f1497b8x
H-D
USA
68830-98
8-34
Circuit Board
f1506x8x
HOME
6.
7.
Verify that rear fender tip lamp and left turn signal lamp
conduit are positioned on the outboard side of the tail
lamp conduit as shown in Figure 8-37.
8.
CAUTION
Over tightening screws can crack the lense or result in
scratching of the fender paint.
9.
8-35
HOME
8.14
REMOVAL
1.
2.
3.
4.
Depress button on socket terminal side of 2-place Multilock connector to release fender tip lamp assembly
from jumper harness. See Figure 8-42.
INSTALLATION
1.
Mate pin and socket halves of 2-place Multilock connector to attach front fender tip lamp assembly to jumper
harness. See Figure 8-42.
2.
With wires routed along bottom left side, place fender tip
lamp bracket into position aligning holes in bracket with
those in fender.
f2040x8x
4.
5.
6.
Front Fender
Tip Lamp [32]
2-Place Multilock (Black)
8-36
f1348c2x
HOME
the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the
headlamp housing assembly from the vehicle. Locate
the front fender tip lamp connector (black 2-place Multilock). See Figure 8-41.
2.
3.
4.
5.
Fender Tip
Lamp Bracket
Oblong Hole
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNECTORS, REMOVING SOCKET/PIN TERMINALS.
6.
7.
8.
9.
Tee Bolt
Wire Conduit
Trim Strip
f1505x8x
Grommet
Pull wires and Multilock socket terminals through grommet to inboard side of fender. See Figure 8-44. Reaching under left side of fender, release wires from one weld
clip and four metal adhesive clips.
f1504a8x
Socket
Terminals
Brake
Hose
f1503b8x
2-Place
Multilock
Connector
Fender Tip
Lamp Bracket
LEFT SIDE
Figure 8-42. Fender Tip Lamp Assembly
8-37
HOME
14. Depress button on socket terminal side of 2-place Multilock connector to release fender tip lamp assembly
from jumper harness. See Figure 8-42.
f12003x8x
INSTALLATION
1.
b.
c.
d.
e.
f.
2.
Mate pin and socket halves of 2-place Multilock connector to attach front fender tip lamp assembly to jumper
harness. See Figure 8-42.
3.
With wires routed along bottom left side, place fender tip
lamp bracket into position aligning holes in bracket with
those in fender.
CAUTION
5.
6.
7.
Route wire conduit inside trim strip and slide front tee
bolt over conduit. See Figure 8-43. Verify that second
tee bolt is in position at rear of trim strip.
8.
9.
10. Pull Multilock socket terminals and wires through grommet to outboard side of fender. See Figure 8-44.
8-38
3
4
Weld
Clip
Fender
Bracket
1WARNING
If any portion of the jumper harness crosses over the riveted fender bracket, contact with the tire can cause chafing or other damage. Damage to the wiring can lead to
loss of lighting while riding, which could result in death
or serious injury.
13. Verify that no portion of the jumper harness crosses over
the riveted fender bracket.
1WARNING
If the height of any metal clip is above the riveted fender
bracket, contact with the tire can cause damage that
results in premature tire failure, which could result in
death or serious injury.
14. Using finger pressure, bend arm of each clip down over
wires so that no portion of the clip is above the height of
the fender bracket.
15. Route socket housing of front fender tip lamp connector
upward behind chrome skirt (FLHT/C/U) or through bottom of headlamp nacelle (FLHR) to area of top fork
bracket. Mate pin and socket halves.
HOME
NOTE
To connect front fender tip lamp with the outer fairing
installed (FLHT/C/U models), reach in below the fairing cap
on the left side of the steering head.
Screwdriver
16. Install the front wheel. See Section 2.2 FRONT WHEEL,
INSTALLATION.
17. Install new cable strap to secure front fender tip lamp
wires to brake line hose. Cut any excess cable strap
material.
18. FLHT/C/U: Install the outer fairing, if removed. See Section 2.27 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
OUTER FAIRING/WINDSHIELD, INSTALLATION.
FLHR: Install wire connector at the back of the headlamp bulb. Align holes in headlamp housing with those in
headlamp nacelle. Install eight Phillips screws. Install
the headlamp door (chrome ring) and door screw.
19. Turn Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.
Lense
f1501x8x
Gasket
Fender Tip
Lamp Bracket
REMOVAL
1.
Rear Fender
Tip Lamp [45]
TORX
Screws
f1500x8x
Opening
f1498x8x
2.
3.
4.
5.
8-39
HOME
NOTE
Fender
Hole
Fender Tip
Lamp Bracket
4.
Feed 3-place Multilock socket and conduit through bottom fender hole. See Figure 8-48.
5.
6.
7.
8.
9.
Orient 3-place Multilock socket so that the release button is at the top and insert into pin housing until it
clicks.
f1499x8x
6.
7.
8.
9.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNECTORS, REMOVING SOCKET/PIN TERMINALS.
INSTALLATION
1.
2.
NOTE
For instructions on crimping wire terminals, see APPENDIX
B.2 AMP MULTILOCK ELECTRICAL CONNECTORS,
CRIMPING INSTRUCTIONS.
3.
Chamber
Number
Black
Not Used
Black
8-40
CAUTION
HOME
8.15
GENERAL
Turn Signal Lamp
Connector [31]
NOTE
If the turn signal does not light after bulb replacment, check
the wiring, the handlebar switch and/or the turn signal module.
FLHT/C/U, FLHR/C
The front turn signals are mounted to the passing lamp
bracket at the front of the vehicle. The rear turn signals are
mounted to a light bar at the rear of the vehicle.
BULB REPLACEMENT
1.
8820
Passing
Lamp
Turn Signal
Lamp
Lense
Lense
Screw
Figure 8-49. Front Turn Signal Lamp
2.
3.
8-41
HOME
7.
f1348c2x
INSTALLATION
1.
Lay old turn signal lamp next to new turn signal lamp
and cut wires to length.
2.
Strip 3/16 inch (4.8 mm) of insulation off new lamp wires
and crimp on new socket terminals.
NOTE
3.
Reattach mechanics wire to socket terminals and carefully pull ends of mechanics wire to draw socket terminals back through conduit.
4.
5.
Right Side
Chamber
Wire Color
Chamber
Blue (DOM)
Black
Violet/Brown
Violet/Brown
Black
Blue (DOM)
7.
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNECTORS, REMOVING SOCKET/PIN TERMINALS.
4.
5.
Mechanics Wire
8-42
Socket Terminal
f1418x2x
HOME
8.
Tail Lamp
[93]
Left Turn
Signal Lamp
[18]
Right Turn
Signal Lamp
[19]
2.
3.
4.
5.
6.
Remove saddlebag on same side of vehicle. See Section 2.23 SADDLEBAG, REMOVAL.
7.
8.
f1498x8x
Pick
Tool
Opening
Fender Hole
Figure 8-54. Release Left Turn Signal Lamp Socket
f1497x8x
INSTALLATION
1.
8-43
HOME
2.
Chamber
Number
Violet/Brown
Black
NOTE
For instructions on properly installing wire terminals, see
APPENDIX B.2 AMP MULTILOCK ELECTRICAL CONNECTORS, INSTALLING SOCKET/PIN TERMINALS.
4.
5.
6.
7.
Orient 2-place Multilock socket so that the release button is at the top and insert into pin housing until it
clicks.
8.
9.
8-44
HOME
8.16
REMOVAL
NOTE
The turn signal/security module also houses the bank angle
sensor.
IMPORTANT NOTE
If equipped with the optional Harley-Davidson Factory
Security System, verify that the security status lamp in
speedometer face is not flashing before proceeding
(security system disarmed).
1.
2.
3.
4.
Remove turn signal/security module from cavity and disconnect 12-place Deutsch connector [30].
Spring
Clip
Turn Signal/Security
Module [30]
f2013x8x
INSTALLATION
1.
2.
3.
4.
8-45
HOME
NOTES
8-46