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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 8

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7.

Install the left and right handlebar switch controls. See

Section

8.22 HANDLEBAR SWITCHES, INSTALLA-

f2056x2x

1

TION.

8.

FLHR/C/S: Install the handlebar clamp shroud. See

2

Section

2.32 WINDSHIELD/HEADLAMP NACELLE

(FLHR/C/S), NACELLE INSTALLATION

(FLHR/C),

steps

3-15, or NACELLE INSTALLATION (FLHRS),

3

steps 5-13.

FLTR: Install the instrument nacelle. See Section 2.31

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

NACELLE, INSTALLATION.

FLHX, FLHT/C/U: Install the fairing cap. See Section

*9

4

2.30 UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/

U), FAIRING CAP, INSTALLATION. Install the radio (or

storage box). See Section

8.32 ADVANCED AUDIO

SYSTEM (FLHX, FLHTC/U, FLTR), RADIO (STORAGE

BOX), INSTALLATION.

5

**10

9.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

6

10.

Turn the ignition/light key switch to IGNITION and test

each handlebar switch for proper operation.

7

11.

Apply front brake hand lever to test operation of brake

lamp.

5

**11

12.

Adjust idle and throttle control cables as follows:

Non-Cruise: See Section 2.21 THROTTLE CABLES

8

(NON-CRUISE), ADJUSTMENT.

Cruise Equipped: See Section 8.31 CRUISE CON-

TROL (FLHRC, FLHTCU, FLTR), CABLE ADJUST-

1.

Screw

MENT.

2.

Flat washer

*LEFT CLAMP ONLY

3.

Upper clamp

9.

Ground cable

4.

Lower clamp

5.

Cup washer

LEFT HAND GRIP

**RIGHT CLAMP ONLY

6.

Spacer

7.

Rubber bushing

10. Flat washer

8.

Bolt

11. Large flat washer

REMOVAL

Figure 2-121. Handlebar Clamp Assemblies

1.

Remove the left handlebar switch controls. See Section

8.22 HANDLEBAR SWITCHES, REMOVAL.

2.

Use a sharp blade to carefully cut rubber and then peel

5.

Tighten upper handlebar clamp screws as follows:

off handlebar.

a. Tighten front screws until upper and lower handle-

3.

Thoroughly clean handlebar to remove all residual adhe-

bar clamps make contact.

sive.

b. Tighten rear screws to 12-16 ft-lbs (16.3-21.7 Nm).

c. Tighten front screws to 12-16 ft-lbs (16.3-21.7 Nm).

INSTALLATION

NOTE

A slight gap will exist between the upper and lower clamps at

1WARNING

the rear of the handlebars after tightening.

HARLEY-DAVIDSON ADHESIVE contains METHYL

6.

Install the left hand grip. See LEFT HAND GRIP,

ETHYL KETONE, a chemical known to the State of Cali-

INSTALLATION, in this section.

fornia to cause cancer or other reproductive harm.

2-98

2006 Touring: Chassis

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Left Side

1WARNING

8.

Holding lower handlebar clamp to prevent rotation, turn

Use HARLEY-DAVIDSON ADHESIVE in well ventilated

bolt at bottom of upper fork bracket until free.

areas only. Vapors are flammable and can be harmful to

9.

Remove lower handlebar clamp, ground wire ring termi-

breath. Avoid contact with eyes, mucous membranes, or

nal and cup washer at top of upper fork bracket.

prolonged contact with skin. Keep out of reach of chil-

10. Pull bushing from fork bracket bore and discard. See

dren.

Figure 2-123.

1.

Obtain a new left hand grip and HARLEY-DAVIDSON

11. Moving to bottom of upper fork bracket, remove bolt and

ADHESIVE (Part No. 99839-95). Apply a coat of the

cup washer.

adhesive to the inside surface of the grip one inch (25.4

mm) from the open end. Apply a coat to the end of the

12. Pull bushing and spacer from fork bracket bore. Remove

handlebar.

spacer from bushing. See Figure 2-125. Discard bush-

ing.

2.

Immediately push grip completely onto end of handlebar

using a twisting motion. Do not hesitate when installing

grip or adhesive may dry before installation is complete.

INSTALLATION

NOTE

If the left hand grip is patterned, align it with the pattern on

Right Side

the right grip with the throttle in the fully closed position.

1.

Insert spacer into new bushing until flush with outboard

3.

Let 6-8 hours elapse (at 70° F.) to allow adhesive to fully

side of collar. See Figure 2-125.

cure.

2.

Insert bushing into bore at bottom of upper fork bracket

4.

Install the left handlebar switch controls. See Section

fitting collar of bushing over lip of boss.

8.22 HANDLEBAR SWITCHES, INSTALLATION.

f2077x2x

RUBBER MOUNTS

NOTE

For complete disassembly of the handlebar clamp assem-

blies and/or to replace the rubber mounts, proceed as fol-

lows.

REMOVAL

General

1.

Turn fork to left fork stop and loosen right side bolt at

bottom of upper fork bracket. Turn fork to right fork stop

and loosen left side bolt at bottom of upper fork bracket.

Figure 2-122. Remove Flat Washer and

Upper Cup Washer (Right Side)

2.

Remove handlebars. See HANDLEBAR REMOVAL in

this section.

f2076x2x

Right Side

3.

Holding lower handlebar clamp to prevent rotation, turn

bolt at bottom of upper fork bracket until free.

4.

Remove lower handlebar clamp, flat washer and cup

washer at top of upper fork bracket. See Figure 2-122.

5.

Pull bushing from fork bracket bore and discard. See

Figure 2-123.

6.

Moving to bottom of upper fork bracket, remove bolt,

large flat washer and cup washer. See Figure 2-124.

7.

Pull bushing and spacer from fork bracket bore. Remove

spacer from bushing. See Figure 2-125. Discard bush-

ing.

Figure 2-123. Remove Upper Bushing (Right Side)

2006 Touring: Chassis

2-99

HOME

10. Moving to top of upper fork bracket, insert bushing into

f2058x2x

bore fitting collar of bushing over lip of boss. See Figure

2-123.

11. Install cup washer over threaded end of bolt fitting con-

cave side over collar of bushing. Install ground wire ring

terminal.

12. Apply two or three drops of Loctite Medium Strength

Threadlocker 243 (blue) to threads of bolt and start lower

handlebar clamp. Holding clamp to prevent rotation, turn

bolt at bottom of upper fork bracket until snug.

General

Figure 2-124. Remove Bolt, Large Washer

13. Install handlebars and upper handlebar clamps. See

and Lower Cup Washer (Right Side)

HANDLEBAR INSTALLATION in this section, steps 1-5.

14. Turn fork to left fork stop and tighten right side bolt at

f2057x2x

bottom of upper fork bracket to 30-40 ft-lbs (40.7-54.2

Nm). Turn fork to right fork stop and tighten left side bolt

to the same torque value.

15. Complete assembly of motorcycle. See HANDLEBAR

INSTALLATION in this section, steps 7-12.

Figure 2-125. Remove Spacer From Lower Bushing

3.

Install large flat washer and cup washer on bolt. See Fig-

ure 2-124. Insert bolt into bushing fitting concave side of

cup washer over collar of bushing.

4.

Moving to top of upper fork bracket, insert bushing into

bore fitting collar of bushing over lip of boss. See Figure

2-123.

5.

Install cup washer over threaded end of bolt fitting con-

cave side over collar of bushing. Install flat washer. See

Figure 2-122.

6.

Apply two or three drops of Loctite Medium Strength

Threadlocker 243 (blue) to threads of bolt and start lower

handlebar clamp. Holding clamp to prevent rotation, turn

bolt at bottom of upper fork bracket until snug.

Left Side

7.

Insert spacer into new bushing until flush with outboard

side of collar. See Figure 2-125.

8.

Insert bushing into bore at bottom of upper fork bracket

fitting collar of bushing over lip of boss.

9.

Install cup washer on bolt. Insert bolt into bushing fitting

concave side of cup washer over collar of bushing.

2-100

2006 Touring: Chassis

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MIRRORS

2.24

2.

With the post on the outboard side, place the plastic

ALL MODELS (EXCEPT FLHX)

washer against the inner fairing engaging two holes in

washer with threaded stud and index pin. The letters “L”

or “R” are stamped on the posts to differentiate between

Removal

left and right side washers.

1.

Remove acorn nut and lock washer. Remove threaded

stem of mirror from hole in clutch or brake lever bracket.

3.

Install flange nut on threaded stud and tighten to 20-30

See Figure 2-126.

in-lbs (2.3-3.4 Nm). See Figure 2-127.

4.

Adjust mirror as necessary.

Installation

5.

Install outer fairing. See Section 2.30 UPPER FAIRING/

1.

Insert threaded stem of mirror into hole in clutch or brake

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

lever bracket.

WINDSHIELD, INSTALLATION.

2.

Install lock washer and acorn nut.

3.

Adjust mirror as necessary and tighten acorn nut to 60-

96 in-lbs (6.8-10.8 Nm).

9291

f2355x2x

1.

Acorn Nut

2.

Lock Washer

3

3.

Mirror

2

Figure 2-127. Remove Outer Fairing (FLHX)

1

Figure 2-126. Mirror Assembly (All Models Except FLHX)

1

2

FLHX

6

Removal

1.

Remove outer fairing. See Section 2.30 UPPER FAIR-

3

ING/WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIR-

ING/WINDSHIELD, REMOVAL.

2.

Standing at front of inner fairing, remove flange nut and

5

plastic washer. Remove mirror. See Figure 2-127.

f2395x2x

4

1.

Threaded Stud

4.

Plastic Washer

Installation

2.

Index Pin

5.

Post and Stamp

1.

With the rounded side of the mirror on the outboard side

3.

Swivel Block Stamp

6.

Flange Nut

(and the bar and shield logo right side up), insert

threaded stud and index pin on swivel block through

Figure 2-128. Left Side Mirror Assembly (FLHX)

holes in inner fairing. See Figure 2-128. The letters “L” or

“R” are stamped on the swivel blocks to differentiate

between left and right side mirrors.

2006 Touring: Chassis

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SEAT

2.25

FLHR

1

2

REMOVAL

1.

Remove Phillips screw to detach passenger seat mount-

ing bracket from top of rear fender. See Figure 2-129.

Slightly lift up back of passenger seat and carefully slide

toward rear of motorcycle to detach from front seat

mounting bracket nuts.

NOTE

The FLHR seat can be converted to a solo seat by removal of

the passenger section. When the solo seat configuration is

desired, turn the passenger seat upside down and locate the

chrome plug pressed into the seat frame hole. See inset of

Figure 2-129. Remove the plug and press into the seat reten-

tion nut hole using finger pressure only.

f1416x2x

2.

Using the 5/8 hex, remove two nuts from studs to free

front seat mounting bracket from rear fender.

f2171x2x

4

2

f1091d2x

1

3

3

5

1.

Seat Bottom

3.

Frame Backbone

2.

Tongue

4.

Slot

Figure 2-130. Seat Mounting

4

3.

Push front seat rearward to free tongue from slot

in

frame backbone. See Figure 2-130.

6

1.

Passenger Seat

INSTALLATION

2.

Phillips Screw

3.

Nut

1.

Position front seat on frame with mounting bracket

at

f1456x2x

4.

Stud Plate

rear.

5.

Front Seat

2.

Firmly push front of seat downward and rearward until

6.

Passenger Seat Retention Nut Plug

tongue engages slot in frame backbone. See Figure 2-

130. Push seat forward until studs are centered in slots

Figure 2-129. Seat Assembly - FLHR

of mounting bracket.

2-102

2006 Touring: Chassis

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3.

Using the 5/8 hex, install two nuts on studs to secure

front seat mounting bracket to rear fender.

f1550x2x

4.

Install passenger seat fitting slots on passenger seat

Slot

front mounting bracket between rounded caps and hex

of front seat mounting bracket nuts.

5.

Push passenger seat forward until rear fender seat

retention nut is centered in hole of rear mounting

bracket. Install Phillips screw and tighten to 20-40 in-lbs

(2.3-4.5 Nm).

NOTE

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

1WARNING

After installing seat, pull upward on front of seat to be

Figure 2-131. Route Passenger Seat Strap Through

sure it is in locked position. While riding, a loose seat

Slots in Seat - FLHRC

can shift causing loss of control, which could result in

death or serious injury. (00070a)

NOTE

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

FLHRC

1WARNING

REMOVAL

After installing seat, pull upward on front of seat to be

sure it is in locked position. While riding, a loose seat

1.

Remove right side saddlebag. See Section 2.26 SAD-

can shift causing loss of control, which could result in

DLEBAG, REMOVAL.

death or serious injury. (00070a)

2.

Remove bolt (with flat washer) to remove passenger

4.

Using slots in seat, route free end of passenger seat

seat strap and saddlebag front mounting bracket from

strap to right side of motorcycle. See Figure 2-131.

chrome frame tube cover.

5.

Insert bolt with flat washer through passenger seat strap

3.

Using slots in seat, carefully pull passenger seat strap

and slotted hole of saddlebag front mounting bracket.

from seat. See Figure 2-131.

Insert bolt into forward hole in chrome frame tube cover.

Snug saddlebag front mounting bracket bolt, but do not

4.

Remove Phillips screw to detach seat mounting bracket

tighten.

from top of rear fender.

6.

Install right side saddlebag. See Section 2.26 SADDLE-

5.

Push seat rearward to free tongue at front of seat from

BAG, INSTALLATION.

slot in frame backbone. See Figure 2-130.

7.

Using an open end/box wrench, tighten saddlebag front

6.

Remove seat from frame.

mounting bracket bolt to 60-96 in-lbs (6.8-10.8 Nm).

INSTALLATION

FLHRS, FLHX, FLTR

1.

Place seat on frame backbone.

2.

Firmly push front of seat downward and rearward until

REMOVAL

tongue engages slot in frame backbone. See Figure 2-

130.

CAUTION

3.

Push seat forward until rear fender seat retention nut is

centered in hole of mounting bracket. Install Phillips

Removing seat without first removing passenger seat

screw and tighten to 20-40 in-lbs (2.3-4.5 Nm).

strap will result in damage to rear fender paint.

2006 Touring: Chassis

2-103

HOME

1.

Remove right side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

2.

Remove bolt (with flat washer) to remove passenger

seat strap and saddlebag front mounting bracket from

chrome frame tube cover. Draw free end of passenger

seat strap to left side of motorcycle.

3.

Remove Phillips screw to detach seat mounting bracket

from top of rear fender.

4.

Push seat rearward to free tongue at front of seat from

slot in frame backbone. See Figure 2-130.

5.

Remove seat from frame.

INSTALLATION

9290

1.

Place seat on frame backbone.

Figure 2-132. Seat Strap Bracket Screw (FLHT/C/U)

2.

Firmly push front of seat downward and rearward until

tongue engages slot in frame backbone. See Figure 2-

130.

1.

Remove left side saddlebag. See Section 2.26 SAD-

3.

Push seat forward until rear fender seat retention nut is

DLEBAG, REMOVAL.

centered in hole of mounting bracket. Install Phillips

2.

Remove Phillips screw to release passenger seat strap

screw and tighten to 20-40 in-lbs (2.3-4.5 Nm).

from seat strap bracket. A firm tug may be necessary to

NOTE

free end of strap from slot of seat strap bracket. See Fig-

ure 2-132.

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

3.

Draw free end of passenger seat strap to right side of

motorcycle.

4.

Remove Phillips screw to detach seat mounting bracket

1WARNING

from top of rear fender.

After installing seat, pull upward on front of seat to be

5.

Push seat rearward to free tongue at front of seat from

sure it is in locked position. While riding, a loose seat

slot in frame backbone. See Figure 2-130.

can shift causing loss of control, which could result in

death or serious injury. (00070a)

6.

Remove seat from frame.

4.

Draw free end of passenger seat strap to right side of

motorcycle. Insert bolt with flat washer through passen-

INSTALLATION

ger seat strap and slotted hole of saddlebag front mount-

ing bracket. Insert bolt into forward hole in chrome frame

1.

Place seat on frame backbone.

tube cover. Snug saddlebag front mounting bracket bolt,

but do not tighten.

2.

Firmly push front of seat downward and rearward until

tongue engages slot in frame backbone. See Figure 2-

5.

Install right side saddlebag. See Section 2.26 SADDLE-

130.

BAG, INSTALLATION.

3.

Push seat forward until rear fender seat retention nut is

6.

Using an open end/box wrench, tighten saddlebag front

centered in hole of mounting bracket. Install Phillips

mounting bracket bolt to 60-96 in-lbs (6.8-10.8 Nm).

screw and tighten to 20-40 in-lbs (2.3-4.5 Nm).

NOTE

FLHT

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

REMOVAL

1

WARNING

After installing seat, pull upward on front of seat to be

CAUTION

sure it is in locked position. While riding, a loose seat

Removing seat without first removing passenger seat

can shift causing loss of control, which could result in

strap will result in damage to rear fender paint.

death or serious injury. (00070a)

2-104

2006 Touring: Chassis

HOME

4.

Draw free end of passenger seat strap to left side of

4.

Push seat forward until rear fender seat retention nut is

motorcycle.

centered in hole of mounting bracket. Install Phillips

screw and tighten to 20-40 in-lbs (2.3-4.5 Nm).

5.

Start Phillips screw to fasten passenger seat strap to

seat strap bracket. Feed end of strap into slot of seat

NOTE

strap bracket and tighten Phillips screw to 48-72 in-lbs

(5.4-8.1 Nm). See Figure 2-132.

If seat retention nut is damaged or lost, see SEAT RETEN-

TION NUT REPLACEMENT for instructions.

6.

Install left side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

1WARNING

After installing seat, pull upward on front of seat to be

sure it is in locked position. While riding, a loose seat

FLHTC/U

can shift causing loss of control, which could result in

death or serious injury. (00070a)

REMOVAL

5.

Draw free end of passenger seat strap to left side of

motorcycle.

1.

Remove left side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

6.

Start Phillips screw to fasten passenger seat strap to

seat strap bracket. Feed end of strap into slot of seat

2.

Remove Phillips screw to release passenger seat strap

strap bracket and tighten Phillips screw to 48-72 in-lbs

from seat strap bracket. A firm tug may be necessary to

(5.4-8.1 Nm). See Figure 2-132.

free end of strap from slot of seat strap bracket. See Fig-

ure 2-132.

7.

Install left side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

3.

Draw free end of passenger seat strap to right side of

motorcycle.

4.

Open Tour-Pak to move passenger seat backrest out of

SEAT RETENTION NUT REPLACEMENT

the way.

NOTE

1.

Slide retention nut over tapered end of cable strap so

that larger OD of nut rests on cable strap eyelet. From

The Tour-Pak must be moved to one of two rearward posi-

bottom of rear fender, feed cable strap up through fender

tions to access the seat mounting bracket screw. If installed

hole.

in the forward position, remove Tour-Pak and install in a rear-

ward position. See Section 2.27 TOUR-PAK for more infor-

2.

See Figure 2-133. With tab on retention nut seated in

mation.

notch of fender hole, pull up on cable strap to hold nut

snug against underside of rear fender. From the side

5.

Remove Phillips screw to detach seat mounting bracket

opposite the tab, slide on the retention washer to lock

from top of rear fender.

the position of the retention nut. Remove cable strap.

6.

To protect finish of Tour-Pak, cover rear seat mounting

bracket with palm of hand.

7.

While pushing seat forward, raise rear of seat until

bracket clears top of Tour-Pak. Push seat rearward

1

4

slightly to free tongue at front of seat from slot in frame

backbone. See Figure 2-130.

8.

Remove seat from frame.

INSTALLATION

1.

Place seat on frame backbone.

3

2

2.

To protect finish of Tour-Pak, cover rear seat mounting

f1897x2x

bracket with palm of hand.

3.

While raising rear of seat approximately 3 inches (76.2

1.

Rear Fender

3.

Tab

mm), use other hand to firmly push front of seat down-

2.

Retention Nut

4.

Retention Washer

ward and rearward until tongue engages slot in frame

backbone. See Figure 2-130.

Figure 2-133. Seat Retention Nut and Washer

2006 Touring: Chassis

2-105

HOME

SADDLEBAG

2.26

OPENING

NOTE

Maximum recommended load for each saddlebag is 15 lbs.

FLHRC

1.

Raise the decorative buckle and press tabs on both

2

1

sides of catch to release from receptacle. Repeat step to

release second catch. See upper frame of Figure 2-134.

2.

Rotate hinge on outboard side of saddlebag to open lid.

FLHRS

1.

Depress button on front inboard side of saddlebag, and

f1554x2x

while holding button in, raise lid. See lower frame of Fig-

ure 2-134.

5

4

f1552x2x

Catch

Receptacle

3

f1553x2x

FLHRC

1.

Latch

2.

Hinge

4.

Anchor Brackets

3.

Anchor Tabs

5.

Check Strap

Button

Figure 2-135. Open Saddlebag

(FLHR, FLHX, FLHT/C/U, FLTR)

2.

Rotate hinge on inboard side of saddlebag to open lid.

FLHR, FLHX, FLHT/C/U, FLTR

1.

Use key to unlock lid latch if locked.

2.

Pull bottom of latch outward and then lift upward raising

outboard corners of saddlebag lid. See upper frame of

Figure 2-135.

FLHRS

f2228x3x

3.

With top of lid tilted toward motorcycle, carefully lift

inboard side of lid upward disengaging front and rear

Figure 2-134.

Open Saddlebag (FLHRC/S)

anchor tabs from anchor brackets.

2-106

2006 Touring: Chassis

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f1075axx

f1451x2x

Front Mounting

Bracket Bolt

7

6

2

5

3

4

1

1.

Bail Wire

5.

Wire Form

2.

Quick-Release Stud

6.

Front Bracket

3.

Flat Washer

7.

Rear Bracket

4.

Spring Plate

Figure 2-136. Saddlebag Quick-Release Fasteners

4.

Pivot lid on latch hinge to open. A nylon check strap sus-

pends the lid in the open position. See lower frame of

Figure 2-135.

CLOSING

Rear Mounting

f1450x2x

Bracket Bolt

FLHRC

Figure 2-137. Saddlebag Mounting Bracket Bolts

1.

Rotate hinge on outboard side of saddlebag to close lid.

(Right Side View)

2.

Insert catch into receptacle until tabs fully engage.

Repeat step to secure second catch. See upper frame of

Figure 2-134.

REMOVAL

FLHRS

1.

Open saddlebag. See OPENING in this section.

1.

Rotate hinge on inboard side of saddlebag to close lid.

2.

Grasp bail wire inside saddlebag and rotate each stud a

Lid latches automatically.

full

1/4 turn in a counter-clockwise direction. Remove

bail head studs with flat washers. See Figure 2-136.

FLHR, FLHX, FLHT/C/U, FLTR

NOTE

1.

Rotate lid to closed position engaging both anchor tabs

On some HDI motorcycles, the bail wire has been removed

with bottom of anchor brackets. Press bottom of latch

from the quick release stud. In these cases, turn the stud by

inward until it snaps closed. See lower frame of Figure 2-

engaging the slotted end with a large screwdriver.

135.

2.

Use key to lock lid latch.

3.

Remove saddlebag.

2006 Touring: Chassis

2-107

HOME

INSTALLATION

Rub Bar

1.

Position saddlebag on motorcycle.

2.

Place flat washers on bail head studs.

3.

With groove at end of stud held in a horizontal position,

insert stud through holes in saddlebag and front mount-

ing bracket. When groove engages wire form of spring

plate on inboard side of bracket, turn stud clockwise a

full 1/4 turn until it snaps in place. Install rear bail head

stud in the same manner.

8862

NOTE

On some HDI motorcycles, the bail wire has been removed

from the quick release stud. In these cases, turn the stud by

engaging the slotted end with a large screwdriver.

NOTE

Molded rubber insert at bottom of saddlebag must fit snugly

on lower saddlebag support rail. If saddlebag is not fully

seated, use an open end/box wrench to loosen bolts secur-

ing mounting brackets to saddlebag support and frame. See

Figure 2-137. Alternately tighten bolts to 60-96 in-lbs (7-11

Nm) after seating saddlebag.

4.

Close saddlebag. See CLOSING in this section.

8863

Figure 2-138. Lid Right Side Up With Latch on Near Side

LATCH SPRING REPLACEMENT

(FLHR, FLHX, FLHT/C/U, FLTR)

Opening

REMOVAL

1.

Lay clean pad or blanket on work bench to protect

painted surfaces of saddlebag.

2.

Remove saddlebag from motorcycle leaving lid open.

See REMOVAL in this section.

3.

Lay saddlebag flat on pad with the inboard side facing

up and the lid closest to you.

8864

4.

Remove two T20 TORX screws to release check strap

from lid.

5.

Remove two T15 TORX screws to release check strap

from saddlebag.

6.

Remove two remaining T15 TORX screws to remove

latch from saddlebag. Move saddlebag back and out of

the way.

CAUTION

This procedure assumes that the latch is NOT removed

8865

from the saddlebag lid. If there is doubt as to whether the

procedure can be accomplished without scratching

Figure 2-139. Lid Up Side Down With Latch on Far Side

painted surfaces of the lid, then remove the five remain-

ing T15 TORX screws to completely remove latch.

2-108

2006 Touring: Chassis

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7.

Position lid right side up with latch closest to you.

9.

Install two T20 TORX screws to fasten check strap to lid.

Alternately tighten screws to 18-20 in-lbs (2.0-2.3 Nm).

8.

Raise latch slightly and rotate hinge on inboard side so

that it is topside with the two plastic rub bars pointed

10. Close saddlebag and install on motorcycle. See

upward. See upper frame of Figure 2-138.

INSTALLATION in this section.

9.

Rotate rub bar section of hinge to expose hinge pin and

spring. Using a flat tip screwdriver, carefully bend

crimped end link outward. See lower frame of Figure 2-

CABLE ASSEMBLY/LATCH/SCRIPT

138.

(FLHRS)

NOTE

The end link on opposite side of hinge has a weld spot that

prevents pin removal.

CABLE ASSEMBLY

10. Reposition lid so that it is upside down with the latch

Removal

farthest from you. Rotate hinge so that plastic rub bars

are positioned beneath latch and spring is topside.

1.

Open saddlebag. See OPENING in this section.

11. Using a needle nose pliers, grasp pin through opening

2.

Remove two screws on inboard side of saddlebag to

just outboard of the spring and push toward the crimped

release plastic shroud. See upper frame of Figure 2-140.

link side. Work pin in this manner until end can be seen

3.

Depress wireform and pull button from hole in saddle-

exiting crimped link. See upper frame of Figure 2-139. If

bag. See lower frame of Figure 2-140.

necessary, pry crimped link outward a little more to

achieve the desired result.

4.

Remove sleeve from hole in saddlebag.

5.

Moving to inboard side of saddlebag lid, remove lock

12. Grasping end with needle nose pliers, slowly pull pin

from links until spring can be slid off opposite end. Only

ring from hole at end of latch pin. See left frame of Fig-

ure 2-141.

pull pin as far as necessary to remove spring. See lower

frame of Figure 2-139.

6.

Pull latch pin from metal shroud, saddlebag bracket and

latch. Remove metal shroud.

INSTALLATION

1.

Slide new spring onto end of pin. Orient spring as shown

in lower frame of Figure 2-139.

2.

Slide pin back through links. Using tapered end of

needle nose pliers, push end of pin into crimped link

3.

Reposition lid so that it is right side up with latch closest

to you. As before, raise latch slightly and rotate hinge on

inboard side so that it is topside with plastic rub bars

pointing upward. Now rotate rub bar section of hinge to

expose hinge pin and spring. See Figure 2-138.

Plastic

4.

Holding lid down with elbow, if necessary, use a pliers to

Shroud

f2229x2x

bend crimped link back into its original position, so that

pin is captured and will not back out of hinge.

5.

Reposition lid so that it is upside down with the latch

farthest from you. Move saddlebag forward for

reinstallation of lid. Align four holes in saddlebag with

those in latch.

6.

Install two inboard T15 TORX screws to fasten latch to

saddlebag. Alternately tighten screws to 20-25 in-lbs

(2.3-2.8 Nm).

7.

Align holes in check strap with those in lid and

saddlebag. Orient check strap so that logo is topside

with the bottom of the bar and shield on the lid side.

Wireform

8.

Install two T15 TORX screws to fasten check strap and

f2232x2x

latch to saddlebag. Alternately tighten screws to 20-25

in-lbs (2.3-2.8 Nm).

Figure 2-140. Remove Button Assembly

2006 Touring: Chassis

2-109

HOME

1. Lock Ring

2. Metal Shroud

3. Latch Slot

4. Saddlebag Bracket

4

5. Spring

6. E-Clip

2

1

3

5

6

f2233x2x

f2234x2x

Figure 2-141. Remove Latch Assembly

7.

Depress spring and pull on cable ball end to remove

9.

Install metal shroud over latch and saddlebag bracket. At

from slot in latch. Remove latch.

rear of assembly, insert latch pin through metal shroud,

saddlebag bracket and latch until end exits front hole in

8.

Remove spring from cable. See right frame of Figure 2-

shroud.

141.

9.

Remove e-clip from groove in cable end fitting.

10. Install lock ring into hole at end of latch pin. See left

frame of Figure 2-141.

10. Pull cable end fitting from hole in saddlebag bracket.

11. Close and open saddlebag lid several times to verify that

11. Release cable from channel running along inboard edge

latch locks every time. Adjust cable if necessary.

of saddlebag.

Installation

Adjustment

1.

From the outboard side, insert sleeve into hole in saddle-

1.

Open saddlebag. See OPENING in this section.

bag.

2.

Remove two screws on inboard side of saddlebag to

2.

On the inboard side, depress wireform and slide button

release plastic shroud. See upper frame of Figure 2-140.

into sleeve. Release wireform. Gently tug on assembly

to verify that wireform has engaged groove in sleeve to

3.

Back jam nut away from body hex. See Figure 2-142.

lock button in place. See lower frame of Figure 2-140.

4.

Turn body hex toward or away from jam nut until closest

3.

Holding plastic shroud with the relief positioned over the

part of latch is approximately 3/8 inch (9.5 mm) from

cable adjuster, install two screws from inboard side of

inboard side of saddlebag lid.

saddlebag. See upper frame of Figure 2-140.

4.

Capture cable in channel running along inboard edge of

saddlebag.

5.

Install cable end fitting into hole in saddlebag bracket.

Body Hex

6.

With the rounded edge of the e-clip on the same side as

the rounded edge of the saddlebag bracket, install e-clip

into groove in cable end fitting.

7.

Pull up on cable ball end and install spring on cable. See

right frame of Figure 2-141.

NOTE

Verify that ball end on opposite side of cable is installed in

pivot of button assembly. See Figure 2-142.

Jam Nut

f2235x2x

8.

Position latch between saddlebag bracket with the cable

slot inline with the cable ball end. Depress spring and

Figure 2-142. Cable Adjustment

capture cable ball end in slot of latch.

2-110

2006 Touring: Chassis

HOME

2

1

3

1

7

4

FLHTC/U

Multi-Rail

Saddlebag Guard

3

f2247x2x

Torque:

6

1. Saddlebag mounting bracket screws: 60-96 in-lbs (7-11 Nm)

2. Saddlebag support to fender screws: 15-20 ft-lbs (20-27 Nm)

3. Rail to saddlebag support screws: 15-20 ft-lbs (20-27 Nm)

4

4. Guard/support rail to frame screws: 15-20 ft-lbs (20-27 Nm)

5

4

5. Support rail to guard screw: 70-100 in-lbs (8-11 Nm)

6. Guard mount to rail screws: 72-120 in-lbs (8-14 Nm)

7. Rail clamp screws: 30-50 in-lbs (3-6 Nm)

3

Saddlebag Guard

FLHR/C, FLHT

f2248x2x

4

5

3

FLHRS, FLHX, FLTR

Saddlebag Support Rail

f2249x2x

4

Figure 2-143. Saddlebag Guards/Support Rail

2-112

2006 Touring: Chassis

HOME

TOUR-PAK

2.27

FLHTC

f2422x8x

4

REMOVAL

2

1.

Open Tour-Pak. Remove rubber mat.

2.

Rotate knurled lock ring in a counter-clockwise direction

to separate pin and socket halves of radio antenna cable

1

connector [51]. Release cable from two adhesive clips at

bottom of Tour-Pak.

3.

Disconnect Tour-Pak lights connector [12], 3-place Mul-

tilock. See Figure 2-144.

4.

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

ness conduit.

5.

Feed main harness conduit and connectors through hole

3

1.

Adhesive Clip

in Tour-Pak. See Figure 2-145.

2.

Radio Antenna Cable Connector [51D]

6.

Holding nylon cap locknuts at bottom of luggage rack

3.

Grommet

rail, remove four hex head bolts (with flat washers) from

4.

Tour-Pak Hole

inside Tour-Pak. Luggage rack spacers will become free

as locknuts are removed.

Figure 2-145. Feed Main Harness Thru Tour-Pak Hole

7.

Holding button head bolt at rear center hole, remove

locknut (and flat washer) from inside Tour-Pak to release

Tour-Pak from luggage rack. Be sure to have a firm

INSTALLATION

grasp on the Tour-Pak as the bolt is removed. See Fig-

1.

Place Tour-Pak on luggage rack and open lid.

ure 2-146.

2.

Align rear center hole in Tour-Pak with same hole in lug-

gage rack. Slide button head bolt through spacer (con-

cave side up), luggage rack and Tour-Pak holes. From

inside Tour-Pak, install flat washer, radio antenna ground

f2421x8x

ring terminal and locknut on bolt. With concavity on

spacer inline with the rail, hold locknut and tighten bolt

4

until snug.

CAUTION

Always install hex head bolts from inside Tour-Pak. If hex

1

head bolts are installed upside down, then loss of a

nylon cap could cause the end of a bolt to tear the

molded liner and scratch objects, such as helmets,

stored inside the Tour-Pak.

3

3.

From inside Tour-Pak, install two hex head bolts (with flat

2

washers) in two front Tour-Pak and luggage rack holes

(one each side). At bottom of luggage rack, install

spacer (concave side up) and nylon cap locknut on each

bolt. With concavity on spacer inline with the rail, hold

1.

Radio Antenna Cable

locknut and tighten each bolt until snug.

2.

Adhesive Clip

3.

Tour-Pak Lights Connector [12]

4.

Position two spacers between bottom of luggage rack

4.

Grommet

and tabs of license plate bracket. Slide two hex head

bolts

(with flat washers) through two center holes in

Figure 2-144. Disconnect Tour-Pak Lights Connector

Tour-Pak and luggage rack, and then through spacers

2006 Touring: Chassis

2-113

HOME

and tabs of license plate bracket. If necessary, loosen

two hex head bolts at back of license plate bracket to

f2388x2x

align holes in tabs with bolts. Install flat washers and

nylon cap locknuts on bolts and tighten until snug. See

inset of Figure 2-146.

5.

In a crosswise pattern, alternately tighten five bolts to

2,4

96-108 in-lbs (10.8-12.2 Nm). Be sure that concavity on

5

each spacer is inline with the rail and has not rotated out

of position.

6.

Standing on left side of motorcycle, feed socket connec-

4

tors and main harness conduit through hole in Tour-pak.

Capture conduit in grommet. Install grommet in hole with

the larger OD facing inside.

7.

Connect Tour-pak lights connector [12], 3-place Mul-

tilock. See Figure 2-144.

8.

Rotate knurled lock ring in a clockwise direction to mate

pin and socket halves of radio antenna cable connector

[51]. Capture cable in two adhesive clips at bottom of

Tour-Pak.

9.

Install rubber mat. Close Tour-Pak.

3

FLHTCU

1

REMOVAL

6

1.

Open Tour-Pak. Open map pocket and remove acorn

nuts

(with flat washers). Remove map pocket and

4

molded liner from Tour-Pak.

2.

Depress external latch and rotate housing to release

bulb socket from left side of Tour-Pak.

3.

Rotate knurled lock ring in a counterclockwise direction

to separate pin and socket halves of radio antenna cable

2,6

3

connector [51]. Release cable from two adhesive clips at

bottom of Tour-Pak.

4.

Disconnect Tour-Pak lights connector [12], 3-place Mul-

tilock. See Figure 2-144.

5.

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

ness conduit.

6.

Feed main harness conduit and connectors through hole

in Tour-Pak. See Figure 2-145.

f1851x2x

7.

Release rear headset receptacle from bracket at bottom

of left side speaker box.

1.

Button Head Bolt- Rear Center Hole (Cap Down)

8.

Remove trim ring and gently pull on wire harness to

2.

Hex Head Bolt (4), 1-3/4 Inch (Cap Up)

draw rear speaker/passenger controls connector [42], 6-

3.

Spacer (5)

place Deutsch, out of left side speaker box. Depress

4.

Flat Washer (7)

external latch and use a rocking motion to separate pin

5.

Locknut

and socket halves.

6.

Nylon Cap Locknut (4)

9.

Moving to right side of motorcycle, disconnect CB

antenna cable connector [50]. Release cable from two

Figure 2-146. Install Tour-Pak Mounting Bolts

adhesive clips at bottom of Tour-Pak. See Figure 2-147.

2-114

2006 Touring: Chassis

HOME

f2423x8x

CAUTION

Always install hex head bolts from inside Tour-Pak. If hex

head bolts are installed upside down, then loss of a

3

nylon cap could cause the end of a bolt to tear the

molded liner and scratch objects, such as helmets,

stored inside the Tour-Pak.

3.

From inside Tour-Pak, install two hex head bolts (with flat

washers) in two front Tour-Pak and luggage rack holes

(one each side). At bottom of luggage rack, install

spacer (concave side up) and nylon cap locknut on each

2

bolt. With concavity on spacer inline with the rail, hold

locknut and tighten each bolt until snug.

4

1

4.

Position two spacers between bottom of luggage rack

and tabs of license plate bracket. Slide two hex head

bolts

(with flat washers) through two center holes in

Tour-Pak and luggage rack, and then through spacers

1.

CB Antenna Cable Connector [50]

and tabs of license plate bracket. If necessary, loosen

2.

Adhesive Clip

3.

Grommet

two hex head bolts at back of license plate bracket to

align holes in tabs with bolts. Install flat washers and

4.

Tour-Pak Mounting Bolt

nylon cap locknuts on bolts and tighten until snug. See

inset of Figure 2-146.

Figure 2-147. Disconnect CB Antenna Cable Connector

5.

In a crosswise pattern, alternately tighten five bolts to

96-108 in-lbs (10.8-12.2 Nm). Be sure that concavity on

each spacer is inline with the rail and has not rotated out

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

of position.

CB antenna cable. Feed CB antenna cable through hole

6.

Connect rear speaker/passenger controls connector

in Tour-Pak.

[41], 6-place Deutsch. Feed connector back up into right

11. Remove trim ring and gently pull on wire harness to

side speaker box pressing trim ring into hole.

draw rear speaker/passenger controls connector [41], 6-

place Deutsch, out of right side speaker box. Depress

7.

Pass CB antenna cable through hole in Tour-Pak. Cap-

ture cable in grommet. Install grommet in hole with the

external latch and use a rocking motion to separate pin

and socket halves.

larger OD facing inside.

12. Holding nylon cap locknuts at bottom of luggage rack

8.

Connect CB antenna cable connector

[50]. Capture

rail, remove four hex head bolts (with flat washers) from

cable in two adhesive clips at bottom of Tour-Pak. See

inside Tour-Pak. Luggage rack spacers will become free

Figure 2-147.

as locknuts are removed.

9.

Moving to opposite side of motorcycle, connect rear

13. Holding button head bolt at rear center hole, remove

speaker/passenger controls connector

[42],

6-place

locknut (and flat washer) from inside Tour-Pak to release

Deutsch. Feed connector back up into left side speaker

Tour-Pak from luggage rack. Be sure to have a firm

box pressing trim ring into hole.

grasp on the Tour-Pak as the bolt is removed. See Fig-

10.

Capture rear headset receptacle in bracket at bottom of

ure 2-146.

left side speaker box.

11.

Feed socket connectors and main harness conduit

through hole in Tour-pak. Capture conduit in grommet.

INSTALLATION

Install grommet in hole with the larger OD facing inside.

1.

Place Tour-Pak on luggage rack and open lid.

12.

Connect Tour-pak lights connector [12], 3-place Mul-

tilock. See Figure 2-144.

2.

Align rear center hole in Tour-Pak with same hole in lug-

gage rack. Slide button head bolt through spacer (con-

13.

Rotate knurled lock ring in a clockwise direction to mate

cave side up), luggage rack and Tour-Pak holes. From

pin and socket halves of radio antenna cable connector

inside Tour-Pak, install flat washer, radio antenna ground

[51]. Capture cable in two adhesive clips at bottom of

ring terminal and locknut on bolt. With concavity on

Tour-Pak.

spacer inline with the rail, hold locknut and tighten bolt

until snug.

14.

Install bulb socket on left side of Tour-pak.

2006 Touring: Chassis

2-115

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