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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 9

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f2397x2x

Figure 2-148. Adjust Position of Tour-Pak for Passenger Comfort

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

ring terminal and locknut on bolt. With concavity on

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

spacer inline with the rail, hold locknut and tighten bolt

Pak.

until snug.

CAUTION

ADJUSTMENT

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

head bolts are installed upside down, then loss of a

NOTE

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

molded liner and scratch objects, such as helmets,

The Tour-Pak can be moved forward/rearward approximately

stored inside the Tour-Pak.

one inch for best passenger comfort.

7.

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

1.

Proceed as follows:

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

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

FLHTC: Open Tour-Pak. Remove rubber mat.

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

FLHTCU: Open Tour-Pak. Open map pocket and

bolt and tighten until snug.

remove acorn nuts (with flat washers). Remove map

8.

Verify that two spacers are in position between bottom of

pocket and molded liner from Tour-Pak.

luggage rack and tabs of license plate bracket. Slide two

2.

From inside Tour-Pak, remove plastic plug from unused

rear center hole.

9426

3.

Holding nylon cap locknuts at bottom of luggage rack

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

inside Tour-Pak. Luggage rack spacers will become free

as locknuts are removed.

4.

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

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

ure 2-146.

5.

Move Tour-Pak to the forward/rearward position. See

Figure 2-148.

6.

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

Figure 2-149. Right Side Luggage Rack Rail (FLHTCU)

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hex head bolts (with flat washers) through two center

holes in Tour-Pak and luggage rack, and then through

1

A

3

spacers and tabs of license plate bracket. Install flat

washers and nylon cap locknuts on bolts and tighten

until snug. See inset of Figure 2-146.

1.

Lockset

9.

In a crosswise pattern, alternately tighten five bolts to

2.

Thin Washer

96-108 in-lbs (10.8-12.2 Nm).

3.

Cam Stop

4

4.

Threaded Stud

10. Verify that wire harness to Tour-pak is not bunched or

stretched at any point. Rearrange wire harness slightly if

9307

2

necessary. Install new cable straps capturing wire har-

ness and luggage rack rails if rearrangement required

cutting of existing cable straps. See Figure 2-149.

f2398x2x

B

11. From inside Tour-Pak, install plastic plug in unused rear

center hole. See Figure 2-148.

12. Proceed as follows:

FLHTC: Install rubber mat. Close Tour-Pak.

6

FLHTCU: Install molded liner in Tour-Pak. Install map

pocket and secure using acorn nuts (with flat washers).

Close Tour-Pak.

5.

Cam Washer

5

6.

Cam Hook

LOCKSET, HINGES, LATCHES,

Figure 2-151. Lockset Mechanism

CATCHES, TETHER, TETHER

BRACKETS

1.

At inside of Tour-Pak lid, remove hex nut, internal tooth

lockwasher, cam hook and cam washer. Remove jam

LOCKSET

nut and lock guide. See Figure 2-150.

Removal

2.

At outside of Tour-Pak, remove lockset. Remove thin

washer from threaded body of lockset. See A of Figure

NOTE

2-151.

For replacement of the lockset catch, see BODY LATCHES/

LOCKSET CATCH in this section.

Installation

1.

Slide thin washer down threaded body of lockset. See A

of Figure 2-151.

1

2.

With cam stop facing toward front of Tour-Pak lid, install

lockset into hole.

3.

Install lock guide over threaded body of lockset oriented

4

with finger at rear and pointing toward bottom of Tour-

Pak lid. See Figure 2-150.

4.

Install jam nut and tighten to 30-45 in-lbs (3.4-5.1 Nm).

2

5.

Verify that groove in threaded stud of lockset is facing

5

rear of Tour-Pak lid. Use key to rotate threaded stud, if

3

7

necessary.

6

6.

Align cam hook and cam washer as shown in B of Figure

9300

2-151. With the cam hook toward the front of Tour-Pak lid

and cam washer on the inboard side, slide assembly

1.

Lock Guide

down threaded stud.

2.

Jam Nut

4.

Cam Washer

6.

Lockwasher

3.

Lockset

5.

Cam Hook

7.

Hex Nut

7.

Install internal tooth lockwasher and hex nut onto

threaded stud. Tighten hex nut to 25-35 in-lbs (2.8-4.0

Figure 2-150.

Lockset Assembly

Nm).

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HINGES

1.

Lockset Catch

3

Removal

2.

T15 TORX Screw

3.

Front Latch

1.

Remove tether. See TETHER, REMOVAL, steps 1-2.

2.

Holding hinge pin with a T25 TORX bit (inboard side),

remove T15 TORX screw (outboard side).

3.

Remove hinge pin from hinge.

1

4.

Repeat steps 2-3 to remove second hinge pin. Remove

Tour-Pak lid.

5.

Using a 3/16 inch drill bit, drill out eight rivets from inside

Tour-Pak.

9363

2

6.

Remove hinge and backplates.

Figure 2-153. Front Latch Assembly

Installation

1.

With the head of the new rivet on the outboard side of

the Tour-Pak, slide rivet through holes in hinge, Tour-Pak

8.

Apply a small dab of Loctite High Strength Threadlocker

and backplate.

262 (red) to threads of T15 TORX screw.

2.

Obtain RIVET TOOL (HD-39787A). See Figure 2-152.

9.

Install T15 TORX screw into hinge pin and tighten to 20-

25 in-lbs (2.3-2.8 Nm).

3.

Orient tool so that head of rivet is seated in depression

of drive head. Turn adjuster thumbscrew in or out of han-

10. Repeat steps 7-9 to install second hinge pin.

dle until both ends of rivet are captured.

11. Install tether. See TETHER, INSTALLATION, steps 1-4.

4.

Slowly squeeze handle of tool to compress rivet. Turn

adjuster thumbscrew slightly in a clockwise direction and

then squeeze handle again to further compress rivet.

LATCHES/LOCKSET CATCH

Repeat step as necessary until rivet is fully installed.

Removal

NOTE

1.

Remove two T15 TORX screws (with flat washers) to

Compress rivet in small increments only. This method

release rear latch and spacer from right side of Tour-

provides for best retention and alignment of parts and avoids

Pak.

possible damage to tool and painted surfaces of Tour-Pak.

2.

Remove two T15 TORX screws to release front latch,

5.

Repeat steps 1-4 to install remaining rivets.

spacer and lockset catch from Tour-Pak. See Figure 2-

153.

6.

Install lid onto Tour-Pak engaging upper and lower

hinges.

Installation

7.

Install hinge pin with the T25 TORX bit recess on the

1.

From inside Tour-Pak, slide two short T15 TORX screws

inboard side of the hinge.

(with flat washers) through rear holes on right side of

Tour-Pak.

2.

With open side of spacer facing Tour-Pak and rib at bot-

tom, slide spacer over ends of screws.

3.

Apply a small dab of Loctite Medium Strength Thread-

locker 243 (blue) to threads of screws and start into

Adjuster

threaded bosses on latch. Properly oriented, portion of

Thumbscrew

latch not mated with spacer should be at the top.

4.

Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

5.

Slide two long T15 TORX screws through holes in lock-

set catch. From inside Tour-Pak, slide screws through

front holes on right side of Tour-Pak. Properly oriented,

Drive

flat side of lockset catch should be topside. See Figure

Head

2-153.

6.

With open side of spacer facing Tour-Pak and rib at bot-

Figure 2-152.

Rivet Tool (HD-39787A)

tom, slide spacer over ends of screws.

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7.

Apply a small dab of Loctite Medium Strength Thread-

locker 243 (blue) to threads of screws and start into

1

threaded bosses on latch. Properly oriented, portion of

latch not mated with spacer should be at the top.

8.

Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

6

5

CATCHES

3

Removal

1.

Using a 3/16 inch drill bit, drill out two rivets from inside

4

Tour-Pak lid.

2

9308

2.

Remove catch and backplate.

1.

Tether Bracket (Lid)

4.

Wave Spring

2.

T15 TORX Screw

5.

Black Nylon Rivet

Installation

3.

Tether Eyelet

6.

Flange Nut

1.

With the head of the new rivet on the outboard side of

Figure 2-154. Tour-Pak Tether Bracket Assembly

the Tour-Pak, slide rivet through holes in catch, Tour-Pak

lid and backplate.

2.

Install rivets. See HINGES, INSTALLATION, steps 2-4.

TETHER BRACKETS

Removal

TETHER

Tour-Pak

Removal

1.

Remove tether. See TETHER, REMOVAL, steps 1-2.

CAUTION

2.

Using a 3/16 inch drill bit, drill out four rivets from inside

Tour-Pak.

Exercise caution to keep lid from opening beyond the

normal 90° of travel or damage to painted surfaces can

3.

Remove tether bracket and backplate.

occur.

1.

Remove T15 TORX screw from threaded boss on tether

Tour-Pak Lid

bracket. See Figure 2-154.

1.

Remove tether. See TETHER, REMOVAL, steps 1-2.

2.

Remove tether eyelet and wave spring from threaded

boss.

2.

From inside Tour-Pak lid, center a 3/32 inch punch on pin

at center of black nylon rivet. Using a small hammer,

3.

Repeat steps 1-2 to remove opposite end of tether from

gently tap pin out of rivet. At outside of Tour-Pak, pull

second tether bracket.

rivet from holes in tether bracket, Tour-Pak lid and pas-

senger backrest bracket. Repeat step to remove second

nylon rivet. See Figure 2-154.

Installation

3.

Remove two flange nuts from studs of passenger back-

1.

With the concave side toward the tether bracket, install

rest bracket and remove tether bracket.

wave spring onto threaded boss.

2.

Install tether eyelet onto threaded boss.

3.

Apply a small dab of Loctite High Strength Threadlocker

Installation

262 (red) to threads of T15 TORX screw.

Tour-Pak Lid

4.

Install screw into threaded boss and tighten to 20-25 in-

lbs (2.3-2.8 Nm). See Figure 2-154.

1.

From inside Tour-Pak lid, install tether bracket on studs

5.

Repeat steps 1-4 to fasten opposite end of tether to sec-

of passenger backrest bracket and start flange nuts. See

ond tether bracket.

Figure 2-154.

2006 Touring: Chassis

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TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX

2.28

GENERAL

9657

All domestic model Ultra Tour-Paks are equipped with side

marker lights. Ultra models also have rear wrap-around

lights, each of which contains a 2-filament lamp. One filament

is a supplemental brake light and the other a supplemental

tail lamp.

SIDE MARKER LIGHTS (FLHTCU)

REMOVAL

1.

Open Tour-Pak. Open map pocket and remove acorn

nuts

(with flat washers). Remove map pocket and

molded liner from Tour-Pak.

Figure 2-155. Side Marker Lights Assembly (FLHTCU)

2.

Disconnect side marker lights connector, 2-place Mul-

tilock.

5.

Close Tour-Pak. Turn Tour-Pak over and remove five

3.

Remove two T15 TORX screws and feed socket through

remaining flange nuts at bottom.

hole in Tour-Pak to release side marker lights. See Fig-

ure 2-155.

6.

Place Tour-Pak topside up and open lid. Reach inside

Tour-Pak and remove metal plate pulling threaded studs

from holes at bottom.

INSTALLATION

7.

Remove masking tape as necessary to release Tour-Pak

1.

Feeding socket through hole in Tour-Pak, place side

lights harness.

marker lights into position. See Figure 2-155.

2.

Align threaded bosses in side marker lights with holes in

INSTALLATION

Tour-Pak. Install two T15 TORX screws and alternately

tighten to 20-25 in-lbs (2.3-2.8 Nm).

1.

Place Tour-Pak lights harness at bottom of Tour-Pak as

3.

Connect side marker lights connector, 2-place Multilock.

shown in Figure 2-156. Adjust harness so that Multilock

connectors are outboard of the metal plate, when

4.

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

installed, and conduit is routed through gaps in ribbing.

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

Use masking tape as necessary to fix position of har-

Pak.

ness and connectors.

CAUTION

TOUR-PAK LIGHTS HARNESS

If conduit is not routed through gaps in ribbing, and con-

nectors are not outboard of the metal plate, tightening of

the flange nuts can pinch wires or crack connectors.

REMOVAL

2.

Install metal plate at bottom of Tour-Pak so that threaded

1.

Remove Tour-Pak. See Section

2.27 TOUR-PAK,

studs exit holes at bottom.

FLHTCU, REMOVAL. Move Tour-Pak to bench area.

2.

Open Tour-Pak. Holding hex head screw inside Tour-Pak

3.

Connect two side marker lights connectors, 2-place Mul-

(rear right corner), remove flange nut at bottom to

tilocks. Capture conduit in two adhesive clips at rear of

Tour-Pak.

release loading coil bracket. Remove hex head screw

with external tooth lockwasher.

4.

Install bulb socket of both left and right side wrap-around

3.

Depress external latch and remove bulb socket of both

lights.

left and right side wrap-around lights. See Figure 2-156.

5.

Align hole in loading coil bracket with holes in rear right

4.

Disconnect two side marker lights connectors, 2-place

corner of metal plate and Tour-Pak. Slide hex head

Multilocks. Release conduit from two adhesive clips at

screw (with external tooth lockwasher) through holes. At

rear of Tour-Pak.

bottom of Tour-Pak, install flange nut.

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f2431x2x

1

6

7

5

4

6

3

2

1.

Tour-Pak Lights Harness [12]

2.

Left Wrap-Around Light

4.

Left Side Marker Lights [12-3]

6.

Rib Gap

3.

Right Wrap-Around Light

5.

Right Side Marker Lights [12-2]

7.

Masking Tape

Figure 2-156. Tour-Pak Lights Harness (FLHTCU)

6.

Close lid and turn Tour-Pak over. Install five remaining

REMOVAL

flange nuts on threaded studs of metal plate. Alternately

tighten six flange nuts to 65-70 in-lbs (7.3-7.9 Nm).

1.

Open Tour-Pak. Open map pocket and remove acorn

nuts

(with flat washers). Remove map pocket and

7.

Install Tour-Pak on motorcycle. See Section 2.27 TOUR-

molded liner from Tour-Pak.

PAK, FLHTCU, INSTALLATION.

2.

Depress external latch and remove bulb socket of both

left and right side wrap-around lights. See Figure 2-156.

3.

Disconnect CB antenna cable connector [50] on right

WRAP-AROUND LIGHTS (FLHTCU)

side of Tour-Pak. Release cable from rear adhesive clip

at bottom of Tour-Pak.

4.

Remove Keps nut, ring terminal and flat washer from

BULB REPLACEMENT

loading coil stud.

1.

Open Tour-Pak. Open map pocket and remove acorn

5.

Holding hex head screw, remove flange nut at bottom of

nuts

(with flat washers). Remove map pocket and

Tour-Pak to release loading coil bracket. Remove hex

molded liner from Tour-Pak.

head screw (with external tooth lockwasher) and loading

2.

Depress external latch and remove bulb socket of left or

coil from motorcycle.

right side wrap-around light. See Figure 2-156.

6.

Using a 2.5 mm allen head wrench, remove loading coil

3.

Remove bulb from socket. Install new bulb.

stud. Remove CB antenna mast from lamp housing.

4.

Install bulb socket of left or right side wrap-around light.

7.

On left side of Tour-Pak, rotate knurled lock ring in a

5.

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

counter-clockwise direction to disconnect radio antenna

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

cable connector [51]. Release cable from rear clip at bot-

Pak.

tom of Tour-Pak.

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2006 Touring: Chassis

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5.

On right side of Tour-Pak, install CB antenna mast into

f2286x2x

lamp housing. Install stud into mast and tighten with 2.5

mm allen head wrench.

1

6.

Place loading coil into position aligning hole in bracket

with hole in rear right corner of Tour-Pak. Slide hex head

screw (with external tooth lockwasher) through holes. At

bottom of Tour-Pak, install flange nut on hex head screw.

7.

Install flat washer, ring terminal and Keps nut onto load-

ing coil stud. Tighten Keps nut.

8.

Connect CB antenna cable connector

[50]. Capture

antenna cable in rear adhesive clip at bottom of Tour-

Pak.

9.

Install bulb socket of both left and right side wrap-around

lights.

4

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

3

secure using acorn nuts. Close Tour-Pak.

2

11. Check SWR and adjust if necessary. Follow the SWR

1.

Tour-Pak

3.

Bulb Housing

Adjustment procedure in Section 6 of the 2006 ELEC-

2.

Caulking

4.

Metal Clip

TRICAL DIAGNOSTIC MANUAL (Part No. 99497-06).

Remove SWR meter, install antenna connector and

Figure 2-157. Wrap-Around Light Assembly

tighten antenna connector stud.

PASSENGER BACKREST/RUBBER

8.

Remove jam nut from radio antenna cable connector at

back of Tour-Pak. Remove internal tooth lockwasher,

ISOLATORS (FLHTCU)

ring terminal and large flat washer from connector.

9.

Install jam nut back onto connector. Thread a 1/2 in.-20

UNF nut onto connector until contact is made with jam

PASSENGER BACKREST

nut. Turn jam nut to in a counter-clockwise direction to

REMOVAL

remove connector stud from radio antenna mast.

Remove mast from lamp housing.

1.

Open Tour-Pak.

10. Remove caulking from around light bar. Remove four

2.

Remove two flange nuts and backplate to release center

flange nuts and metal clips to free light bar from Tour-

backrest from Tour-Pak lid. See Figure 2-158.

Pak. See Figure 2-157.

3.

Remove two flange nuts to release left side backrest.

CAUTION

INSTALLATION

Be sure that black nylon rivets are in place before remov-

1.

Install light bar, metal clips and flange nuts to secure

ing flange nuts to release right side backrest or tether

light bar to Tour-Pak. Inside Tour-Pak, use RTV silicone

bracket will come free. Unexpected release of the tether

sealer (Part No. 99710-88) to seal perimeter of light bar.

bracket can allow the Tour-Pak lid to swing fully open,

See Figure 2-157.

which may result in damage to hinges and painted sur-

faces. If black nylon rivets are missing, be sure to hold

2.

Install radio antenna mast into lamp housing. Thread

Tour-Pak lid as the second flange nut is removed.

connector stud into mast. Turn

1/2 in.-20 UNF nut

(installed on connector during removal) in a clockwise

4.

Remove two flange nuts to release right side backrest.

direction to tighten.

5.

Carefully pull studs on backrest brackets from holes in

3. Remove 1/2 in.-20 UNF nut and jam nut. Install large flat

Tour-Pak lid.

washer, ring terminal and internal tooth lockwasher onto

connector. Reinstall jam nut and tighten.

INSTALLATION

4.

Rotate knurled lock ring in a clockwise direction to mate

1.

Slide studs on center backrest cushion plate through

pin and socket halves of radio antenna cable connector

holes in Tour-Pak lid. With the nylon side facing the Tour-

[51]. Capture cable in rear clip at bottom of Tour-Pak.

Pak, install backplate on studs and start flange nuts.

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2.

Proceed as follows:

Center isolator: Remove flange nut with lockwasher to

5142

release cushion plate from rubber isolator stud. Remove

flange nut with lockwasher to release other stud from

backrest support bracket. See Figure 2-159.

4

Outside isolator: Remove flange nut with lockwasher to

3

release "L" bracket from rubber isolator stud. Rotate rub-

ber isolator to remove other stud from threaded hole in

backrest. See Figure 2-160.

Installation

1.

Proceed as follows:

1

Center isolator: Insert stud of new rubber isolator into

hole of backrest support bracket and install lockwasher

and flange nut. Tighten flange nut until snug. Install

cushion plate, lockwasher and flange nut on other stud.

Orient cushion plate so that it is parallel to backrest and

then finger tighten flange nut only. See Figure 2-159.

CAUTION

Always hold rubber isolator on end to be installed. Do

2

not grasp middle of rubber isolator or opposite end as

excessive twisting can result in separation of molded

parts or other damage.

Outside isolator: Install stud of new rubber isolator into

threaded hole in backrest until snug. Install “L” bracket,

lockwasher and flange nut on other stud. Finger tighten

1.

Center Flange Nuts and Backplate

flange nut only. See Figure 2-160.

2.

Left Side Flange Nuts

3.

Right Side Flange Nuts, Tether Bracket and

2.

Install passenger backrest. See PASSENGER BACK-

Black Nylon Rivets

REST, INSTALLATION.

4.

Passenger Backrest

3.

Gently pull back cover material of backrest to expose

Figure 2-158. Tour-Pak Lid (Underside)

underside and final tighten flange nuts only finger tight-

ened in step 1.

4.

Verify that each side of rubber isolator is not twisted or

under any torsional load. Loosen flange nuts and adjust

2.

Slide studs on left side backrest "L" bracket through

rubber isolator if necessary.

holes in Tour-Pak lid and start flange nuts.

3.

Slide studs on right side backrest "L" bracket through

holes in Tour-Pak lid and tether bracket and start flange

PASSENGER BACKREST FLAP

nuts.

(FLHTCU)

4.

Alternately tighten six flange nuts to 40-60 in-lbs (4.5-

6.8 Nm).

5.

Close Tour-Pak.

BACKREST FLAP

REMOVAL

RUBBER ISOLATORS

1.

Open Tour-Pak. Open map pocket and remove two

acorn nuts (with flat washers). Remove map pocket and

Removal

molded liner from Tour-Pak.

1.

Remove passenger backrest. See PASSENGER BACK-

2.

Holding acorn nuts inside Tour-Pak, remove two T25

REST, REMOVAL.

TORX screws (with flat washers) at front.

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SPEAKER BOX (FLHTCU)

9365

2

REMOVAL

1

1.

Remove trim ring and gently pull on wire harness to

draw rear speaker/passenger controls connector [41/42],

6-place Deutsch, out of speaker box. Depress external

latch and use a rocking motion to separate pin and

socket halves.

2.

Open Tour-Pak. Open map pocket and remove acorn

nuts

(with flat washers). Remove map pocket and

molded liner from Tour-Pak.

3

3.

Remove three bolts with flat washers to free speaker box

1.

Cushion Plate

3.

Backrest Support Bracket

from Tour-Pak.

2.

Rubber Isolator

Figure 2-159. Center Isolator

INSTALLATION

9365

1.

Install three bolts with flat washers to secure speaker

box to Tour-Pak. Alternately tighten bolts to 25-35 in-lbs

(2.8-4.0 Nm).

2.

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

1

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

Pak.

3.

Connect rear speaker/passenger controls connector [41/

42],

6-place Deutsch. Feed connector back up into

2

speaker box pressing trim ring into hole.

1.

“L” Bracket

2.

Rubber Isolator

Figure 2-160. Outside Isolator

3.

Remove backrest flap.

INSTALLATION

1.

Align holes in backrest flap with those at front of Tour-

Pak.

2.

Slide two T25 TORX screws (with flat washers) through

holes in backrest flap and Tour-Pak. Inside Tour-Pak,

install acorn nuts.

3.

Holding acorn nuts, alternately tighten screws to 21-24

in-lbs (2.4-2.7 Nm).

4.

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

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

Pak.

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LOWER FAIRING/ENGINE GUARD

2.29

2.

Holding screw inside fairing lower, install new rubber

LOWER FAIRING (FLHTCU)

washer, clamp and locknut to attach bottom of fairing

lower to engine guard. Do not tighten locknut.

3.

Verify that two clip studs are fully installed on fairing cap.

REMOVAL

4.

Position fairing cap at front of engine guard and against

1.

Unfasten snaps to release glove box door flap. Release

fairing lower so that clip studs engage holes in fairing

anchor on draw string from hole in glove box door. Set

lower and glove box tray. Reaching into glove box, start

door flap aside.

two flange nuts on clip studs.

2.

Reaching into glove box, remove two flange nuts from

5.

Verify that fairing lower is square, and then alternately

clip studs and remove fairing cap. If necessary, push

tighten flange nuts on clip studs to 35-40 in-lbs (4.0-4.5

ends of studs through holes in glove box tray and fairing

Nm).

lower to release fairing cap. Do not twist or rotate fairing

6.

Hold locknut at bottom of fairing lower and turn inside

cap or damage may result. See Figure 2-161.

T40 TORX screw to fasten assembly to engine guard

clamp. Tighten screw to 90-100 in-lbs (10.2-11.3 Nm).

3.

Hold locknut at bottom of fairing lower and turn inside

T40 TORX screw to free assembly from engine guard

7.

Repeat steps 1-6 on other side of motorcycle.

clamp. Discard rubber washer.

4.

Repeat steps 1-3 on other side of motorcycle.

DISASSEMBLY

1.

See REMOVAL, steps 1-3.

INSTALLATION

2.

Remove three T20 TORX screws to release glove box

1.

Place fairing lower into position at front of engine guard.

door and glove box tray from fairing lower.

1.

Fairing Lower

15. Flat Washer

7

2.

Engine Guard Clamp

16. Compression Spring

3.

T40 TORX Screw

17. Serrated Washer (1 Black, 1 White)

14

4.

Rubber Washer

18. Pivot Screw

5.

Locknut

19. Vent Door

15

6.

Door Flap

7.

Snap, Push-In (4)

16

6

8.

Flange Nut (2)

1

9.

Clip Stud (2)

10. Fairing Cap

8

11. T20 TORX Screw (5)

13

11

12

12. Glove Box Tray

10

13. Glove Box Door

17

11

14. Locknut

18

3

19

4

9

2

5

f2342x2x

Figure 2-161. Lower Fairing Assembly

2-126

2006 Touring: Chassis

HOME

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

2.30

OUTER FAIRING/WINDSHIELD

T27 TORX Screws

2

1

3

REMOVAL

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2.

Remove the outer fairing and windshield as follows:

a. Standing at the front of the motorcycle, loosen the

three T27 TORX screws (with flat washers) just

40

50

60

70

80

30

40

50

30

90

20

60

below the windshield. See Figure 2-162.

20

100

10

70

100

MPH

110120

0

RPMx100

80

b. Raise and remove the windshield from between the

inner and outer fairings.

c. Moving to the inner fairing side, remove the two

screws outboard of the speakers on the left and

right side.

d. Turn the handlebar to the right and remove screw by

reaching in below the left side of the fairing cap.

Turn the handlebar to the left and remove screw

below right side of the fairing cap.

6

7

4

5

f2357x8x

CAUTION

Figure 2-162. Outer Fairing TORX Screw Locations

On FLHX models, be sure to hold the outer fairing in

position as the last screw is removed. Without auxiliary

lamps to hold it in position, the outer fairing will drop,

possibly resulting in fairing or fender damage.

d. Turn the handlebar to the left and start screw by

e. Returning to the front of the motorcycle, remove the

reaching in below the right side of the fairing cap.

three screws below the windshield.

Turn the handlebar to the right and start screw

below left side of the fairing cap.

f.

Tilting the outer fairing forward, remove headlamp

connector [38] at the back of the headlamp assem-

e. Alternately tighten the four screws on the inner fair-

bly.

ing side to 20-30 in-lbs (2.3-3.4 Nm).

g. Lift the outer fairing off the motorcycle.

f.

Returning to the front of the motorcycle, place the

windshield into position between the inner and outer

fairings engaging the slotted holes in the windshield

INSTALLATION

with the threaded bosses on the inner fairing.

g. Alternately tighten the three screws below the wind-

1.

Install the outer fairing and windshield as follows:

shield to 25-30 in-lbs (2.8-3.4 Nm).

a. Place the outer fairing on the motorcycle and install

headlamp connector [38] at the back of the head-

lamp assembly.

2.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

b. Start the three T27 TORX screws (with flat washers)

just below the windshield. See Figure 2-162.

c. Moving to the inner fairing side, start the two screws

outboard of the speakers on the left and right side.

2006 Touring: Chassis

2-129

HOME

5.

Assemble ignition switch. See Section 8.19 IGNITION/

LIGHT KEY SWITCH AND FORK LOCK, FLHX, FLHT/

Rubber

f1305b2x

Grommet

C/U, FLTR, INSTALLATION, steps 6-15.

INNER FAIRING

REMOVAL

CAUTION

To avoid scratches or other damage, place protective

material over front fender, fuel tank and fairing lowers, if

present.

1.

Remove the outer fairing. See OUTER FAIRING/WIND-

Fairing Cap

Switch Connector [105]

SHIELD, REMOVAL, in this section.

2.

Disconnect left and right front turn signal/auxiliary lamp

Figure 2-163. Fairing Cap Assembly (FLHX, FLHT/C/U)

connectors [31L/R], 4-place Multilocks, on T-studs at top

of left and right fairing support braces (outboard side).

See Figure 2-164.

FAIRING CAP

3.

Remove four T40 TORX screws to release auxiliary lamp

bracket from upper and lower fork brackets. Remove

auxiliary lamp assembly from the motorcycle.

REMOVAL

1.

Partially disassemble ignition switch. See Section 8.19

IGNITION/LIGHT KEY SWITCH AND FORK LOCK,

f2356x8x

FLHX, FLHT/C/U, FLTR, REMOVAL, steps 1-5.

[31R]

[31L]

2.

Remove two T27 TORX screws (with flat washers) to

release fairing cap from left and right sides of inner fair-

ing.

3.

With the front forks turned to the left fork stop, reach

behind right side of fairing cap and disconnect the fairing

cap switch connector [105], 12-place Multilock (black).

4.

Remove the fairing cap from the motorcycle. See Figure

2-163.

INSTALLATION

1.

Verify that the rubber grommets are installed on each

side of the fairing cap. Barbs on cap fit into holes in

grommets. See Figure 2-163.

2.

Connect the fairing cap switch connector [105], 12-place

Multilock (black), on right side of the fairing cap.

Chrome

3.

With the front forks turned to the left fork stop, install fair-

Skirt

ing cap over ignition switch housing. Verify that grom-

mets in fairing cap fully capture handlebar along with

throttle and clutch cables.

[31L] Left Turn Signal/Auxiliary Lamp Connector

4.

Start two T27 TORX screws (with flat washers) to fasten

[31R] Right Turn Signal/Auxiliary Lamp Connector

fairing cap to left and right sides of inner fairing. Alter-

nately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Figure 2-164. Inner Fairing (Front

View)

2-130

2006 Touring: Chassis

HOME

[34]

[110]

[108]

[116]

[35]

[111]

[117]

[21]

[39]

[132]

[112]

[114]

[113]

[115]

[21] Indicator Lamps

[110] Voltmeter Gauge Lamp

[34] Right Front Speaker

[111] Voltmeter Gauge

[115] Air Temperature Gauge

[35] Left Front Speaker

[112] Oil Pressure Gauge Lamp

[116] Fuel Gauge Lamp

[39] Speedometer

[113] Oil Pressure Gauge

[117] Fuel Gauge

[108] Tachometer

[114] Air Temperature Gauge Lamp

[132] Cigarette Lighter

f2356x8x

Figure 2-165. Inner Fairing Connectors (FLHX, FLHTC/U)

4.

Remove the fairing cap. See FAIRING CAP, REMOVAL,

10. Feed clutch cable and cable eyelet through inner fairing

in this section.

grommet to front of motorcycle.

5.

Pull chrome skirt from inner fairing. See Figure 2-164.

CAUTION

6.

Slide rubber boot off clutch cable adjuster. Holding cable

adjuster with 1/2 inch wrench, loosen jam nut using 9/16

Do not remove the switch housing assembly without first

inch wrench. Back jam nut away from cable adjuster.

placing a 5/32 inch (4.0 mm) cardboard insert between

Move adjuster toward jam nut to introduce free play at

the brake lever and lever bracket. Removal without the

hand lever.

insert may result in damage to the rubber boot and

7.

Remove retaining ring from pivot pin groove at bottom of

plunger of the front stoplight switch.

clutch lever bracket. Remove pivot pin.

NOTE

8.

Remove two T27 TORX screws (with flat washers) to

Use the eyelet of a small cable strap if the cardboard insert is

release handlebar clamp from clutch lever bracket.

Remove clutch hand lever from clutch lever bracket.

not available.

9.

Remove anchor pin and clutch cable eyelet from clutch

11. Place the cardboard insert between the brake lever and

hand lever. See Figure 2-114.

lever bracket.

2006 Touring: Chassis

2-131

HOME

14. Remove the brass ferrules from the notches on the

f1345x2x

inboard side of the throttle control grip. For best results,

2

place flat tip screwdriver in slot on outboard side and

rotate ferrule in notch. Remove the ferrules from the

1

cable end fittings.

NOTE

On non cruise equipped models, remove the friction shoe

from the end of the tension adjuster screw. The friction shoe

is a loose fit and may fall out or become dislodged if the lower

switch housing is turned upside down or shaken.

4

15.

Remove the throttle control grip from the end of the han-

5

3

dlebar.

16.

Remove two-sided plastic clip inboard of cable adjuster

6

boots to separate throttle and idle control cable hous-

ings. Pull the crimped inserts at the end of the cable

housings from the lower handlebar switch housing. For

1.

Pin Housing

4.

Mounting Bracket

best results, place a drop of light oil on the retaining

2.

Hex Nut

5.

Tab

rings and use a rocking motion while pulling.

3.

Stud

6.

Gauge

17.

Feed the throttle and idle control cables through the

Figure 2-166. Voltmeter Gauge Assembly

inner fairing grommet to front of motorcycle.

18.

See Figure 2-165. Pull socket terminals

[132] from

spade contacts on cigarette lighter. Remove cigarette

f2262x8x

1

lighter from socket. Holding socket to prevent rotation,

unscrew outer shell. Remove socket from inner fairing.

19.

Pull socket terminals [35] from left side speaker spade

contacts. Remove three T25 TORX screws to release

4

the speaker adapter from the inner fairing. Repeat step

on right side of motorcycle.

20.

Unthread rubber boot from odometer reset switch. Pull

switch from hole in inner fairing.

5

21.

Disconnect speedometer gauge connector

[39] and

tachometer gauge connector [108]. See Figure 2-165.

Leaving anchors on interconnect harness installed in

outboard ears of brackets, remove allen head socket

2

3

screws to remove brackets from gauges. Push gauges

toward rear of motorcycle to remove from inner fairing.

1.

Indicator Lamps Connector [21]

22.

Disconnect indicator lamps connector

[21],

10-place

2.

Paddle

Multilock. See Figure 2-165. Release four paddles to

3.

Lense

free indicator bulb housing from lense assembly. See

4.

Bulb Housing

Figure 2-167. Remove lense assembly from inner fair-

5.

Rubber Boot

ing.

23.

Disconnect the voltmeter gauge lamp connector [110]

Figure 2-167. Indicator Lamp Assembly

and voltmeter gauge connector [111]. Disconnect the

fuel gauge lamp connector [116] and fuel gauge connec-

tor [117].

12.

Using a T25 TORX drive head, remove the upper and

24.

Remove four socket head screws to free inner fairing

lower switch housing screws.

from fairing bracket. See Figure 2-168.

13.

Using a T27 TORX drive head, loosen the upper screw

25.

Spread bottom of inner fairing to free from dowels in

securing the handlebar clamp to the master cylinder

lower fork bracket. Spread bottom of fairing bracket to

housing. Remove the lower clamp screw with flat

release from same dowels.

washer.

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2006 Touring: Chassis

HOME

2.

Install voltmeter and fuel gauges in inner fairing. Slide

mounting brackets over studs. Verify that tabs on top and

bottom of brackets engage slots in inner fairing. Loosely

install hex nuts on studs. Verify that gauge is properly

aligned and tighten nuts to 10-20 in-lbs (1.1-2.3 Nm).

See Figure 2-166. On Classic and Ultra models, repeat

step to install air temperature and oil pressure gauges.

CAUTION

To avoid scratches or other damage, place protective

material over front fender, fuel tank and fairing lowers, if

present.

3.

Remove T40 TORX screws to free fairing bracket (with

radio and interconnect harness) from lower fork bracket.

Raise fairing bracket and then tilt forward at about a 45

degree angle.

4.

Position inner fairing at rear of fairing bracket. Tilting

inner fairing rearward at about a 45 degree angle, align

upper and lower fork bracket thru holes with those in fair-

f2356x8x

ing bracket. Draw fairing bracket and inner fairing

together fitting radio into slot in inner fairing.

Figure

2-168.

Remove Fairing Bracket Screws

5.

Align upper thru holes in fairing bracket and inner fairing

with threaded holes in upper fork bracket and start T40

26.

Raise inner fairing and fairing bracket slightly to prevent

TORX screws. Align lower thru holes in fairing bracket

reengagement with dowels. On Classic and Ultra mod-

and inner fairing with dowels in lower fork bracket and

els, disconnect the oil pressure gauge lamp connector

start screws. Alternately tighten four T40 TORX screws

until snug.

[112], oil pressure gauge connector [113], air tempera-

ture gauge lamp connector [114], and air temperature

6.

Install four socket head screws to attach inner fairing to

gauge connector [115].

fairing brackets. See Figure 2-168.

27.

Raise inner fairing and fairing bracket together and then

7.

Connect the voltmeter gauge lamp connector [110], volt-

separate by pulling fairing bracket toward the front and

meter gauge connector [111], fuel gauge lamp connec-

inner fairing toward the rear.

tor [116], and fuel gauge connector [117]. On Classic

and Ultra models, connect the oil pressure gauge lamp

28.

When inner fairing becomes free of the radio, remove

connector [112], oil pressure gauge connector [113], air

from motorcycle and move to bench area.

temperature gauge lamp connector [114], and air tem-

perature gauge connector [115].

29.

Install fairing bracket (with radio and interconnect har-

ness) back onto motorcycle aligning holes with dowels in

8.

Place indicator lamp lense assembly into inner fairing.

lower fork bracket. Loosely install T40 TORX screws.

Slot at bottom of lense engages tab in inner fairing to

prevent improper orientation. Engage all four paddles on

30.

At bench area, remove hex nuts from studs at back of

lense assembly with slots on indicator bulb housing.

voltmeter and fuel gauges. Remove mounting brackets

Connect indicator lamps connector [21], 10-place Mul-

from gauges and remove gauges from inner fairing. See

tilock. See Figure 2-167.

Figure 2-166. On Classic and Ultra models, repeat step

to remove oil pressure and air temperature gauges.

9.

Install speedometer and tachometer gauges in inner fair-

ing. Align holes in brackets with those at back of gauges

31.

Remove clutch and throttle cable grommets from the

and start two allen head socket screws. Rotate gauges

inner fairing.

until tabs at top and bottom of brackets engage slots in

inner fairing. Verify that gauge is properly aligned and

tighten allen head socket screws to 10-20 in-lbs (1.1-2.3

Nm). Connect speedometer gauge connector [39] and

INSTALLATION

tachometer gauge connector [108].

1.

At bench area, install clutch and throttle cable grommets

10.

Slide odometer reset switch through hole in inner fairing.

in inner fairing.

Install rubber boot to secure.

2006 Touring: Chassis

2-133

HOME

NOTE

5

4

On non cruise equipped models, install the friction shoe with

6

the concave side up so that the pin hole is over the point of

the adjuster screw. The friction shoe is a loose fit and may fall

out or become dislodged if the lower switch housing is turned

upside down or shaken.

16. Push the throttle and idle control cables into the lower

handlebar switch housing until they snap in place. Pro-

ceed as follows:

a. Note the different diameter inserts crimped into the

end of the throttle and idle control cable housings.

b. Push the larger diameter insert (silver) on the throt-

tle cable housing into the larger hole (front).

c. Push the smaller diameter insert (gold) on the idle

cable housing into the smaller hole (rear).

NOTE

1

To aid assembly, place a drop of light oil on the retaining

rings of the crimped inserts. Always replace the retaining

rings if damaged or distorted.

2

17. Slide the throttle control grip over the end of the right

f1474x2x

3

handlebar until it bottoms against the closed end. Rotate

the grip so that the ferrule notches are at the top. To pre-

1.

Throttle Grip

4.

Groove

vent binding, pull the grip back about 1/8 inch (3.2 mm).

2.

Idle Cable

5.

Notch

3.

Throttle Cable

6.

Ferrule

18. Position the lower switch housing beneath the throttle

control grip. Install the brass ferrule onto the throttle

cable so that the end fitting seats in the ferrule recess.

Figure 2-169. Install Throttle/Idle Cables

Be sure that ferrule is oriented so that when installed in

notch of throttle control grip, slotted end is on the out-

board side. Install ferrule in notch of throttle control grip.

11. With the widest edge at the top, align holes in speaker

adapter with those in inner fairing. Install two long

Verify that cable is captured in groove molded into the

screws to fasten top of speaker adapter. Capturing fair-

grip. Repeat step to install idle control cable. See Figure

ing support brace, install short screw in lower outboard

2-169.

hole (positioning flat washer between adapter and sup-

19. Position the upper switch housing over the handlebar

port brace). Using a T25 TORX drive head, tighten the

and lower switch housing.

lower screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten the

two upper screws to 35-50 in-lbs (4.0-5.7 Nm).

20. Verify that the wire harness conduit runs in the depres-

sion at the bottom of the handlebar. Also be sure that the

NOTE

upper switch housing harness will not be pinched

against the handlebar when the switch housing screws

The screw hole on the lower inboard side of the speaker

are tightened.

adapter is not used.

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

12. Push the socket terminals onto the speaker spade con-

not tighten.

tacts. Different size spade contacts prevent improper

assembly.

CAUTION

13. Repeat steps 11-12 on opposite side of motorcycle.

Do not remove the 5/32 inch (4.0 mm) cardboard insert

14. From rear of inner fairing, slide socket of cigarette lighter

(or cable strap eyelet) wedged between the brake lever

through bore in fairing. Thread outer shell onto socket

and lever bracket. Removal will result in damage to the

until tight. Install cigarette lighter in socket. Connect the

rubber boot and plunger of the Front Stoplight Switch

orange/white wire terminal to the socket spade contact,

during installation of the master cylinder assembly.

the black wire terminal to the outer shell contact.

22. Position the brake lever/master cylinder assembly

15. Feed the throttle and idle control cables through the right

inboard of the switch housing assembly engaging the

side inner fairing grommet.

tab on the lower switch housing in the groove at the top

of the brake lever bracket.

2-134

2006 Touring: Chassis

HOME

23. 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

Air

Nm) using a T27 TORX drive head.

Deflector

24. 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.

25.

Remove the cardboard insert between the brake lever

and lever bracket.

Knurled

26.

Install two-sided plastic clip inboard of cable adjuster

f1815x2x

Thumbscrew (3)

boots to hold throttle and idle control cable housings

together.

Figure 2-170. Remove/Install Air Deflectors

27.

Moving to other side of motorcycle, feed clutch cable

through left side inner fairing grommet.

28.

Insert clutch cable eyelet into groove of clutch hand lever

aligning eyelet with hole without bushing. Insert anchor

AIR DEFLECTORS (FLHTCU)

pin through lever and eyelet.

29.

Insert lever into groove of clutch lever bracket fitting

NOTE

sleeve at end of cable housing into bore on inboard side

By increasing the flow of air behind the fairing, removing the

of bracket.

air deflectors evacuates heated air and provides some relief

30.

Align hole in hand lever with hole in bracket and install

to the rider in warmer temperatures (70˚ F. or above).

pivot pin. Install retaining ring in pivot pin groove.

31.

Install two T27 TORX screws (with flat washers) to

REMOVAL

secure handelbar clamp to clutch lever bracket. Starting

with the top screw, tighten screws to 60-80 in-lbs (6.8-

1.

Remove three knurled thumbscrews to release air

9.0 Nm).

deflector at side of inner fairing. See Figure 2-170.

2.

Repeat step to remove air deflector on opposite side of

32.

Adjust the clutch. See Section 6.3 CLUTCH, ADJUST-

motorcycle.

MENT.

NOTE

33.

Install the fairing cap. See FAIRING CAP, INSTALLA-

TION, in this section.

If additional cooling is desired, either vent or remove the fair-

ing lowers, if installed. See Section 2.29 LOWER FAIRING/

34.

Remove two T40 TORX screws from lower fork bracket.

ENGINE GUARD, LOWER FAIRING (FLHTCU).

Install chrome skirt aligning thru holes with screws just

removed. Start T40 TORX screws back into lower fork

bracket. See Figure 2-164.

INSTALLATION

35.

Loosen two T40 TORX screws from upper fork bracket.

NOTE

36.

Slide slots of auxiliary lamp bracket onto upper and

lower fork bracket screws. Alternately tighten four T40

Reinstall air deflectors in colder weather.

TORX screws to 15-20 ft-lbs (20-27 Nm) in a crosswise

1.

Install three knurled thumbscrews to fasten air deflector

pattern.

at side of inner fairing.

37.

Mate left and right front turn signal/auxiliary lamp con-

2.

Repeat step to install air deflector on opposite side of

nectors [31L/R], 4-place Multilocks. Install on T-studs at

motorcycle. See Figure 2-170.

top of left and right fairing support braces (outboard

side). Verify that conduit is routed inboard using relief in

upper outboard corner of chrome skirt.

38.

Install the outer fairing. See OUTER FAIRING/WIND-

SHIELD, INSTALLATION, in this section.

2006 Touring: Chassis

2-135

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