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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 10

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UPPER FAIRING/WINDSHIELD (FLTR)

2.31

WINDSHIELD ONLY

4

2

1

REMOVAL

1.

Standing at front of motorcycle, alternately loosen and

3

then remove five Phillips screws (with plastic flat wash-

ers) at base of windshield.

2.

Remove windshield from outer fairing.

3.

Carefully remove wellnuts

(with rubber flat washers)

from holes in outer fairing. See Figure 2-171. Exercise

5

caution to avoid pushing wellnuts into fairing during

removal. Inspect wellnuts and rubber flat washers for

cuts, tears or signs of deterioration. Replace as neces-

sary.

f2280x2x

INSTALLATION

1.

Phillips Screw

1.

Preinstall hardware on windshield as follows:

2.

Plastic Flat Washer

4.

Wellnut

3.

Windshield

5.

Rubber Flat Washer

a. Slide plastic flat washers onto Phillips screws.

Figure 2-172. Install Windshield

b. Slide Phillips screws through slots in windshield.

(Decal Removed for Illustration Purposes)

c. Slide rubber flat washers onto wellnuts.

d. Start wellnuts onto Phillips screws.

3.

Starting with center screw, alternately tighten the five

Phillips screws to 6-13 in-lbs (0.7-1.5 Nm).

2.

Moving to front of motorcycle, push wellnuts into holes in

outer fairing. See Figure 2-172.

OUTER FAIRING

f1525x2x

REMOVAL

NOTE

Windshield may be left in place during outer fairing removal.

1.

Place protective material on top of front fender to protect

paint from scratches or other damage.

2.

Obtain ratchet and T25 TORX head bit. Standing on left

side of motorcycle, remove screw at edge of fairing out-

board of the left speaker. See Figure 2-173. Remove

screw outboard of the right speaker.

3.

Loosen top left and right screws just outboard of the fuel

and volt gauges, respectively.

4.

Remove screw just below left side glove compartment.

Remove screw below right side glove compartment.

5.

On inboard side of right fairing support, remove rear

acorn nut (with flat washer) from stud of front turn signal

Figure 2-171. Remove Wellnuts From Outer Fairing

lamp bracket. Remove front acorn nut with flat washer.

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2006 Touring: Chassis

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2

2

50

60

70

30

40

50

3040

MPH

80

90

20

RPMx100

60

2010

100110

10

70

0

120

0

80

CERTIFIEDN

N

1

1

HARLEY-DAVIDSON

Long Screw

Long Screw

3

3

f2361x8x

Figure 2-173. Remove/Install Six Outer Fairing Screws

Pull front turn signal lamp assembly from motorcycle

and allow to hang at front of engine guard. Repeat step

9424

to remove front turn signal lamp assembly on left side.

See Figure 2-174.

6.

Remove top left and right screws just outboard of the

fuel and volt gauges, respectively (previously loosened).

7.

Raise outer fairing slightly and then rest on protective

fender pad.

8.

Squeeze two external tabs to disconnect headlamp

jumper harness connector.

9.

To avoid possible wire damage, disconnect front turn

signal lamp connectors [31L] and [31R], 3-place Mul-

tilocks, and move to bench area. See Figure 2-175.

INSTALLATION

Figure 2-174. Remove Acorn Nuts to Release

1.

Place protective material on top of front fender to protect

Turn Signal Lamp and Bracket

paint from scratches or other damage.

2.

Connect front turn signal lamp connectors [31L] and

NOTE

[31R], 3-place Multilocks. Capture conduit in adhesive

The front turn signal lamp assemblies are not interchange-

clips on inner fairing. Allow front turn signal lamp assem-

able. Note that the letters R(ight) or L(eft) are stamped on the

blies to hang at front of engine guard until outer fairing

inboard side of the turn signal lamp bracket to help ensure

installation is complete.

proper assembly.

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2-137

HOME

10. Alternately tighten four short fairing screws to 6-12 in-

lbs (0.7-1.4 Nm). Alternately tighten two long fairing

screws to 10-15 in-lbs (1.1-1.7 Nm). Use the torque pat-

tern shown in Figure 2-173.

11. Slide studs on front turn signal lamp bracket through

holes in fairings and fairing support. Loosely install

acorn nuts with flat washers. Alternately tighten acorn

nuts to 40-50 in-lbs (4.5-5.7 Nm).

12. Repeat step 11 to install front turn signal lamp assembly

on opposite side of motorcycle.

9408

BEZEL

Figure 2-175. Front Turn Signal Lamp

REMOVAL

1.

Remove T25 TORX screw on left and right side of instru-

3.

To avoid chafing wires of interconnect harness, verify

ment bezel. See Figure 2-176.

that trim strips are installed inboard of hooks on radio

bracket.

2.

Use thumbs to push tab at rear of bezel from slot in front

of ignition switch. Gently raise free side of bezel until

4.

Rest outer fairing on front fender pad and connect head-

tabs at front of instrument nacelle become disengaged

lamp jumper harness connector.

from slot at front of bezel (concealed behind decorative

adhesive strip).

CAUTION

3.

Raising bezel slightly, remove anchor on ambient tem-

If windshield is attached during outer fairing installation,

perature sensor from hole in bottom inboard ear

of

exercise caution to avoid scratching or damaging inner

speedometer bracket.

fairing with windshield screws and wellnuts.

5.

Place outer fairing against inner fairing. Two slots in

f2360x8x

1.

T25 TORX Screws

outer fairing must engage hooks on radio bracket. Move

2.

Bezel

harness conduit and wiring as necessary to ensure full

3.

Instrument Nacelle

engagement between outer and inner fairings.

1

6.

Move to side of outer fairing to verify that alignment tabs

are properly engaged. Alignment tabs on inner fairing

must be positioned outboard of those on the outer fair-

ing. Repeat step on opposite side of motorcycle.

NOTE

Although the tightening sequence described below begins on

the left side of the motorcycle, if the left side of the outer fair-

ing fits the inner fairing better than the right, then start the

50

60

70

30

40

50

first screw on the right side. In other words, install the first

40

80

30

MPH

90

20

RPMx100

60

20

100

screw on the side that does not have the best fit.

10

110

10

70

0

120

0

80

CERTIFIEDN

N

7.

Obtain ratchet and T25 TORX head bit. Install screw at

edge of fairing outboard of the left speaker. Install screw

outboard of the right speaker. Mounting bosses on inner

fairing are painted white for easier alignment of holes.

8.

Install the top left and right screws just outboard of the

2

fuel and volt gauges, respectively.

3

9.

Moving to left side of motorcycle, install the first of two

long screws just below the glove compartment. Install

the second long screw below the right side glove com-

partment.

Figure 2-176. Remove Instrument Bezel Screws

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[21] Indicator Lamps

[39] Speedometer Gauge

[105A/B]

[21]

[105A/B] Instrument Nacelle Switches

[105C/D] Speaker Switch

[107] Ambient Temperature Sensor

[108]

[108] Tachometer Gauge

Throttle

Cables

[39]

Clutch

Cable

[105C/D]

[107]

f2219x8x

Figure 2-177. Instrument Nacelle (Bezel Removed)

4.

See Figure 2-177. Disconnect instruments and indicator

NOTE

lamps from interconnect harness as follows:

If tabs do not properly engage slot at front of bezel, then a

● Speedometer connector [39], 12-place Packard.

loose fit will result. Remove decorative adhesive strip by gen-

● Tachometer connector [108], 12-place Packard.

tly prying up outer edges, and using a flat bladed screwdriver,

carefully raise tabs so that they engage lip in slot. If dam-

● Indicator lamps connector [21], 10-place Multilock.

aged, install new decorative adhesive strip.

5.

Remove bezel from motorcycle.

5.

Install T25 TORX screw on each side of bezel. Alter-

nately tighten screws to 25-35 in-lbs (2.8-4.0 Nm). See

Figure 2-176.

INSTALLATION

1.

See Figure 2-177. Looking into the instrument nacelle,

connect instruments and indicator lamps to interconnect

harness as follows:

INSTRUMENT NACELLE

● Speedometer connector [39], 12-place Packard.

● Tachometer connector [108], 12-place Packard.

REMOVAL

● Indicator lamps connector [21], 10-place Multilock.

1.

Partially disassemble ignition switch. See Section 8.19

2.

Install anchor on ambient temperature sensor into hole

IGNITION/LIGHT KEY SWITCH AND FORK LOCK,

in bottom inboard ear of speedometer bracket.

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

3.

Verify that left and right sides of instrument nacelle are

properly mated. Pins on left side of nacelle must fully

2.

Remove bezel. See BEZEL, REMOVAL, in this section.

engage holes on right.

3.

See Figure 2-177. Disconnect left side switch from

4.

Insert tab at rear of bezel into slot of instrument nacelle

instrument nacelle switch harness as follows:

(just in front of ignition switch). Holding left and right

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

sides of nacelle together, place bezel over instrument

nacelle flange. When properly mated, tabs at front of

instrument nacelle engage lip in slot at front of bezel

4.

Pull clutch cable clip from hole on left side of instrument

(behind decorative adhesive strip).

nacelle.

2006 Touring: Chassis

2-139

HOME

5.

Remove two T40 TORX bolts (with flat washers) to

9.

Remove two T40 TORX bolts (with flat washers) to

release left side of instrument nacelle from upper and

release right side of instrument nacelle from upper and

lower fork brackets.

lower fork brackets.

6.

Unthread rubber boot from odometer reset switch, and

while carefully removing left side instrument nacelle from

INSTALLATION

motorcycle, pull odometer reset switch from hole. See

Figure 2-178.

1.

Install right side of instrument nacelle on motorcycle.

2.

See Figure 2-179. Connect instrument nacelle switches

7.

See Figure

2-179. Disconnect instrument nacelle

to interconnect harness as follows:

switches from interconnect harness as follows:

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

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

Multilock.

Multilock.

3.

While carefully placing left side of instrument nacelle on

8.

Pull throttle cable clip from hole on right side of instru-

motorcycle, slide odometer reset switch through hole

ment nacelle.

and install rubber boot.

f2214x8x

CONNECTOR

DESCRIPTION

NUMBER

[A, C] = Pin

[B, D] = Socket

LEFT SIDE

[105A, 105B]

Interconnect to Nacelle Switch Harness

[105]

[105C, 105D]

Nacelle Switch Harness to Speaker Switch

5

RIGHT SIDE

4

3

1.

Instrument Nacelle Switches Connector [105B]

2.

Speaker Switch Connector [105C]

3.

Throttle Cable Clip Hole

4.

Speaker Switch Connector [105D]

5.

Clutch Cable Clip Hole

2

1

f2213x8x

Figure 2-178. Instrument Nacelle Halves

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2006 Touring: Chassis

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[24]

[1]

[51]

[22]

[156]

Radio

Ground

[2]

[31L]

[31R]

[38]

[15]

f2362x8x

[1] Main to Interconnect Harness

[2] Main to Interconnect Harness

[31L] Left Turn Signal

[15] Main to Interconnect Harness

[31R] Right Turn Signal

[22] Right Handlebar Switch Controls

[38] Headlamp

[24] Left Handlebar Switch Controls

[51] Radio Antenna Cable

[27] Radio

[156] Main to Interconnect Harness

Figure 2-179. Inner Fairing Connectors (FLTR)

4.

See Figure 2-179. Connect left side switch to instrument

8.

Install two T40 TORX bolts (with flat washers) to fasten

nacelle switch harness as follows:

right side instrument nacelle to upper and lower fork

brackets. Tighten bolts to 15-20 ft-lbs (20-27 Nm).

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

9.

Capture throttle cables in cable clip. Insert cable clip into

5.

Verify that left and right sides of nacelle are properly

hole in right side of instrument nacelle.

mated. Four pins on left side of nacelle must fully

engage holes on right.

10. Install bezel. See BEZEL, INSTALLATION, in this sec-

tion.

6.

Install two T40 TORX bolts (with flat washers) to fasten

left side instrument nacelle to upper and lower fork

11. Assemble ignition switch. See Section 8.19 IGNITION/

brackets. Alternately tighten bolts to 15-20 ft-lbs (20-27

LIGHT KEY SWITCH AND FORK LOCK, FLHX, FLHT/

Nm).

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

7.

Capture clutch cable in cable clip. Insert cable clip into

hole in left side of instrument nacelle.

2006 Touring: Chassis

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INNER FAIRING

f2237x2x

REMOVAL

1.

Place protective material on top of front fender to protect

paint from scratches or other damage.

Interconnect

Harness

2.

Remove the outer fairing. See OUTER FAIRING,

REMOVAL, in this section.

3.

Carefully cut two cable straps to free wire bundles and

conduit from convoluted tubing of interconnect harness

and allow to hang naturally.

4.

See Figure 2-179. Disconnect main harness from inter-

connect harness as follows:

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

place Deutsch (black); below radio (right side).

Figure 2-180. Wrap Main Harness in Shop Towels

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); below radio (right side).

10.

See Figure 2-177. Draw branches of interconnect har-

● Main to interconnect harness connector [15], 4-

ness (terminating in odometer reset switch and speed-

place Packard (black); below radio (right side).

ometer, tachometer, indicator lamps, instrument nacelle

● Main to interconnect harness connector [156], 6-

switch and ambient temperature sensor connectors)

place Deutsch (gray); below radio (right side).

from instrument nacelle through tunnel of fairing bracket

to front of inner fairing.

5.

See Figure 2-179. Disconnect radio antenna cable and

11.

Disconnect ignition switch connector [33], 3-place Pack-

radio ground wire. Proceed as follows:

ard, at front of ignition switch housing. Proceed as fol-

● Radio antenna cable connector [51]; back of radio

lows:

(left side).

a. Obtain the IGNITION SWITCH CONNECTOR

● Radio ground; single spade and socket terminal;

REMOVER (HD-45961).

below radio (left side).

b. Gently insert end of tool into slot in ignition switch

housing until it stops.

6.

See Figure 2-179. Disconnect handlebar switch controls

c. Grasping main harness conduit and tool, pull both

from interconnect harness. Proceed as follows:

at the same time to release socket housing from

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

ignition switch housing.

place Deutsch (gray); T-stud on left side of radio

bracket.

12.

Draw branch of main harness terminating in ignition

switch connector from instrument nacelle through tunnel

● Right handlebar switch controls connector [22], 12-

of fairing bracket to front of inner fairing.

place Deutsch (black); T-stud on left side of radio

bracket.

13.

Separate any branches of the interconnect harness that

may be intermingled with the main harness conduit.

7.

Draw the main harness conduit, handlebar switch con-

Allow the interconnect harness to hang along the left

trol conduit, radio ground wire and radio antenna cable

side of the front fender.

as far forward as possible. Rest the connectors of the

14.

Capturing all connectors, tightly wrap clean shop towels

longer harnesses on the front fender.

around the main harness conduit, handlebar switch con-

8.

Remove left side of instrument nacelle. See INSTRU-

trol conduit, radio ground wire and radio antenna cable,

MENT NACELLE, REMOVAL, in this section, steps 1-6.

and secure with masking tape. See Figure 2-180.

9.

See Figure

2-177. Disconnect instrument nacelle

15.

Remove four locknuts to release radio bracket and inner

switches and ambient temperature sensor from intercon-

fairing from studs of fairing bracket. See Figure 2-181.

nect harness as follows:

16.

Lift inner fairing (with attached radio bracket and inter-

connect harness) from fairing bracket studs and move to

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

bench area.

Multilock.

NOTE

● Ambient temperature sensor connector [107], 3-

place Multilock.

To remove the fairing bracket, proceed with steps 17-22.

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2006 Touring: Chassis

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1.

Fairing Bracket

7.

Slot

f2105x2x

2.

Bolt

8.

Radio Bracket

3.

Locknut

9.

Locknut

4.

Stud

10. Outer Fairing Hooks

5.

Inner Fairing

11. Trim Strip

5

6.

Opening

10

4

1

11

2

3

7

8

9

6

Figure 2-181. Inner Fairing Assembly

17.

Remove right side instrument nacelle. See INSTRU-

2.

Route handlebar switch control conduit through opening

MENT NACELLE, REMOVAL, in this section, steps 8-9.

at top of fairing bracket. See Figure 2-182.

18.

Remove shop towels and masking tape from around the

3.

Route main harness and both radio ground and harness

harness bundle. Separate main harness conduit, han-

ground ring terminals through opening on right side of

dlebar switch control conduit, radio ground wire and

fairing bracket. See Figure 2-182.

radio antenna cable.

4.

Install screw to fasten harness ground ring terminal and

19.

Remove screw to release main harness ground ring ter-

brake line P-clamp to front of upper fork bracket.

minal and brake line P-clamp from front of upper fork

bracket.

5.

Draw wire harnesses and conduit out tunnel of fairing

bracket and pull as far forward as possible. Tightly wrap

20.

Pull main harness and both radio ground and harness

ground ring terminals through opening on right side of

clean shop towels around radio ground, main harness

fairing bracket allowing conduit and connectors to hang

and handlebar switch control conduit and connectors

over top of engine guard.

and secure with masking tape. See Figure 2-180.

21.

Pull handlebar switch control conduit out through open-

6.

Install right side instrument nacelle. See INSTRUMENT

ing at top of fairing bracket.

NACELLE, INSTALLATION, in this section, steps 8-9.

22.

Remove locknuts and bolts to release fairing bracket

7.

Place protective material on top of front fender to protect

from holes at rear of steering head.

paint from scratches or other damage. Rest inner fairing

(with attached radio bracket and interconnect harness)

on front fender.

INSTALLATION

8.

Place inner fairing over four fairing bracket studs while

NOTE

feeding end of harness bundle through opening beneath

radio. See Figure 2-181. Verify that sides of inner fairing

To install the fairing bracket, begin at step 1. If only the inner

are positioned outboard of both fairing supports

(on

fairing was removed, start at step 7.

engine guards).

1.

Align holes in fairing bracket with those at rear of steer-

9.

Install four locknuts to secure radio bracket and inner

ing head. Standing on right side, insert bolts until they

exit fairing bracket on left side of motorcycle. Install lock-

fairing to fairing bracket studs. Tighten locknuts to 96-

144 in-lbs (10.9-16.3 Nm).

nuts and tighten to 20-30 ft-lbs (27.1-40.7 Nm).

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HOME

10.

Draw the harness bundle as far forward as possible,

of inner fairing through tunnel of fairing bracket and then

resting the end of the bundle on the front fender. See

out through opening at top of fairing bracket to instru-

Figure 2-180.

ment nacelle.

11.

Find branch of interconnect harness terminating in

15.

Connect main harness to ignition switch. Proceed as fol-

odometer reset switch and speedometer, tachometer,

lows:

indicator lamps, instrument nacelle switch and ambient

● Ignition switch connector

[33],

3-place Packard;

temperature sensor connectors. Feed connectors and

front of ignition switch housing.

conduit from front of inner fairing through tunnel of fair-

ing bracket and then out through opening at top of fairing

16.

See Figure 2-179. Connect handlebar switch controls to

bracket to instrument nacelle.

interconnect harness. Proceed as follows:

12.

See Figure 2-177. Connect instrument nacelle switches

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

and ambient temperature sensor to interconnect har-

place Deutsch (gray); T-stud on left side of radio

ness as follows:

bracket.

● Right handlebar switch controls connector [22], 12-

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

place Deutsch (black); T-stud on left side of radio

Multilock.

bracket.

● Ambient temperature sensor connector [107], 3-

place Multilock.

17.

See Figure 2-179. Connect main harness to intercon-

nect harness as follows:

13.

Returning to front of inner fairing, remove shop towels

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

and masking tape from around the harness bundle. Sep-

place Deutsch (black); below radio (right side).

arate radio ground, main harness and handlebar switch

control conduit.

● Main to interconnect harness connector [2], 12-

place Deutsch (gray); below radio (right side).

14.

Find branch of main harness terminating in ignition

● Main to interconnect harness connector [15], 4-

switch connector. Feed connector and conduit from front

place Packard (black); below radio (right side).

● Main to interconnect harness connector [156], 6-

place Deutsch (gray); below radio (right side).

2

f2231x2x

18.

See Figure 2-179. Connect radio antenna cable and

radio ground wire. Proceed as follows:

1

● Radio antenna cable connector [51]; back of radio

(left side).

● Radio ground; single spade and socket terminal;

below radio (left side).

19.

Orient connectors as shown in Figure 2-179. Install two

new cable straps outboard of radio bracket hooks to

secure wire bundles and conduit to convoluted tubing of

interconnect harness. Cut any excess cable strap mate-

rial.

CAUTION

To avoid chafing wires of interconnect harness, verify

that trim strips are installed inboard of hooks on radio

bracket.

4

3

20. Install the outer fairing. See OUTER FAIRING, INSTAL-

LATION, in this section.

1.

Ignition Switch

2.

Left and Right Handlebar Controls

21. Install left side of instrument nacelle. See INSTRUMENT

3.

Main Harness

NACELLE, INSTALLATION, in this section, steps 5-7

4.

Radio Ground

and 9-10.

22. Install bezel. See BEZEL, INSTALLATION, in this sec-

Figure 2-182. Route Main Harness and Conduit

tion.

Thru Fairing Bracket

2-144

2006 Touring: Chassis

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WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S)

2.32

1.

Standing at the front of the motorcycle, carefully insert

WINDSHIELD REMOVAL

the windshield brackets between the headlamp nacelle

and the auxiliary lamp bracket. Lower the windshield into

1.

See Figure 2-183. Standing at the front of the motorcy-

position until the lower notches on the windshield brack-

cle, use a finger to raise the wireform latch springs on

ets are seated on the lower grommets.

both sides of the windshield.

2.

Gently push the top of the windshield toward the rear

2.

Gently pull on the top of the windshield until the upper

until the upper notches fully engage the upper grom-

mets. See Figure 2-183.

notches on the windshield brackets are free of the upper

grommets.

3.

Push down on the wireform latch springs, so that they

overhang the rubber grommets. If some adjustment is

3.

Carefully raise the windshield until the lower notches are

necessary, loosen the retaining screws and rotate the

free of the lower grommets.

latch springs into the proper position.

4.

Remove windshield from motorcycle.

NACELLE REMOVAL (FLHR/C)

WINDSHIELD INSTALLATION

1.

Remove the windshield. See WINDSHIELD REMOVAL

on this page.

CAUTION

2.

Remove the Phillips screw at the bottom of the head-

lamp door (chrome ring). Remove the headlamp door.

To avoid scratching headlamp nacelle or auxiliary lamp

bracket, be sure that all four notches on the windshield

3.

Remove the seven Phillips screws to free the headlamp

brackets are firmly seated on a rubber grommet.

housing from the headlamp nacelle.

1

3

2

6

1.

Wireform Latch Spring

2.

Windshield

3.

Headlamp Nacelle

5

4.

Upper Grommet

5.

Auxiliary Lamp Bracket

4

6.

Clutch Cable

f2278x2x

Figure 2-183. Windshield (FLHR/C)

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2006 Touring: Chassis

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9.

Cover the front fender with suitable material to protect

f2195x2x

5

the fender paint. Remove the auxiliary lamp bracket from

the left and right side fork bracket studs and carefully set

8

7

on front fender.

10. Remove the grommets (and clutch cable clamp) from the

left and right side fork bracket studs.

6

11. Raise the handlebar clamp shroud, and after separating

the halves of the headlamp nacelle slightly, slide the

shroud forward running the shaft of the Phillips screw

down the gap. See Figure 2-185.

12. Reaching inside the headlamp nacelle, disconnect

accessory switch connector

[67] and auxiliary lamp

4

1

switch connector [109].

13. Carefully separate the halves of the headlamp nacelle

2

and remove from motorcycle.

3

NACELLE INSTALLATION (FLHR/C)

1.

Fit halves of the headlamp nacelle together engaging

9

the holes in the nacelle with the left and right side fork

bracket studs.

2.

Reaching inside the headlamp nacelle, connect acces-

10

sory switch connector [67] and auxiliary lamp switch

connector [109].

3.

If disassembled, install Phillips screw, flat washer and

Keps nut on the handlebar clamp shroud as shown in

1.

Headlamp Nacelle

6.

Handlebar Clamp

Figure 2-185.

(Left Side)

Shroud

4.

Part the halves of the headlamp nacelle slightly. With the

2.

Trim Strip

7.

Phillips Screw (2)

flat washer on the inboard side of the nacelle, slide the

3.

Flange Nut

8.

Phillips Screw

shroud rearward running the shaft of the Phillips screw

4.

Chrome Strip

9.

Flat Washer

down the gap. Position the shroud over the flange at the

5.

Fork Lock Plate

10.

Keps Nut

top of the nacelle.

Figure 2-184. Headlamp Nacelle Assembly

4.

Remove headlamp connector [38] at back of headlamp

bulb. Remove the headlamp housing assembly from the

motorcycle.

5.

Reaching inside the headlamp nacelle, remove the

flange nut to release the chrome strip at the top of the

nacelle. See Figure 2-184.

6.

Carefully pry off the fork lock plate at the rear of the han-

dlebar clamp shroud. Remove two Phillips screws

beneath the lock plate.

7.

Loosen the Phillips screw from tab at the front of the

handlebar clamp shroud (but do not remove Keps nut

and flat washer).

f1458b2x

8.

Remove the two acorn nuts from the left side fork

bracket studs. Remove acorn nuts from the right side

Figure 2-185. Handlebar Clamp Shroud

fork bracket studs.

and Screw Assembly

2006 Touring: Chassis

2-147

HOME

5.

Mate the halves of the headlamp nacelle and tighten the

Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).

6.

Install two Phillips screws to secure the handlebar clamp

shroud to the fork lock mechanism. Install the fork lock

plate.

1WARNING

To avoid possible damage to the brake hose, throttle

cables and/or handlebar switch wires, verify that trim

strips are installed on inside edges of the headlamp

nacelle. Cutting or severe chafing of the brake hose,

throttle cables and/or handlebar switch wires could

f2194x2x

cause loss of function while riding, possibly resulting in

death or serious injury.

Figure 2-186. Remove Screw From Slot in Wind Deflector

7.

Verify that trim strips are installed on inside edges of

headlamp nacelle. Install new trim strips if cracked, bro-

ken or missing.

8.

Inserting the weld stud on the chrome strip into the hole

at the top of the headlamp nacelle, reach inside the

nacelle to install flange nut. Tighten flange nut to 15-20

in-lbs (1.7-2.3 Nm).

9.

Install the grommets on the left and right side fork studs.

10.

Slide the auxiliary lamp bracket onto the left and right

side fork bracket studs. Verify that the four grommets are

in place on the inboard side of the auxiliary lamp brack-

ets.

11.

Install the acorn nuts on the fork bracket studs and

tighten to 72-108 in-lbs (8.1-12.2 Nm). Be sure to cap-

f2193x2x

ture the clutch cable clamp on the upper left stud before

installing the acorn nut.

Figure 2-187. Handlebar Clamp Shroud/Wind Deflector

12.

Install headlamp connector [38] at back of headlamp

and Screw Assembly

bulb.

13.

Align holes in headlamp housing with wellnuts in head-

lamp nacelle (headlamp door bracket at bottom). Install

3.

Remove headlamp connector [38] at back of headlamp

the seven Phillips screws and alternately tighten to 9-18

in-lbs (1.0-2.0 Nm).

bulb. Remove the headlamp housing assembly from the

motorcycle.

14.

Fit the square-shaped portion of the headlamp door

spring into the slot at the top of the headlamp housing

4.

Reaching inside the headlamp nacelle, remove the

and then snap the headlamp door (chrome ring) into

flange nut to release the chrome strip at the top of the

place. Install Phillips screw at the bottom of the head-

nacelle.

lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).

5.

Carefully pry off the fork lock plate at the rear of the han-

15.

Install the windshield. See WINDSHIELD INSTALLA-

dlebar clamp shroud. Remove two Phillips screws

TION in this section.

beneath the lock plate.

6.

Loosen Phillips screw at front of wind deflector (but do

not remove). Reaching inside the headlamp nacelle,

NACELLE REMOVAL (FLHRS)

release screw head from slot in tab and then draw screw

assembly down and out through headlamp nacelle. See

1.

Remove the Phillips screw at the bottom of the head-

Figure 2-186.

lamp door (chrome ring). Remove the headlamp door.

7.

Raise handlebar clamp shroud/wind deflector and

2.

Remove the seven Phillips screws to free the headlamp

remove from motorcycle. See Figure 2-187.

housing from the headlamp nacelle.

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2006 Touring: Chassis

HOME

FRONT FENDER

2.33

REMOVAL

Front Fender Tip Lamp

Jumper Harness [32]

NOTE

If fender tip lamp is absent, start procedure at step 4.

1.

FLHT/C/U: Reaching in below the fairing cap on the left

side of the steering head, disconnect front fender tip

lamp jumper harness connector [32], 2-place Multilock.

See Figure 2-188. Remove the outer fairing only if nec-

essary. See Section

2.30 UPPER FAIRING/WIND-

SHIELD

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

WINDSHIELD, REMOVAL.

FLHR: Remove the Phillips screw at the bottom of the

headlamp door (chrome ring). Remove the headlamp

door. Remove the seven Phillips screws to free the

headlamp housing from the headlamp nacelle. Remove

headlamp connector [38] at back of headlamp bulb.

Remove the headlamp housing assembly from the

motorcycle. Disconnect front fender tip lamp jumper har-

ness connector [32], 2-place Multilock. See Figure 2-

189.

f2356x8x

Figure 2-188.

Inner Fairing (FLHT/C/U)

2.

Draw socket housing down to fender area.

3.

Carefully cut cable strap to release front fender tip lamp

wires from brake line hose.

4.

Place the motorcycle on a hydraulic center stand with

the front wheel raised off the ground.

5.

Use shop rag or tape to protect fender area adjacent to

caliper, as incidental contact can occur during caliper

removal.

6.

Remove both the upper and lower mounting bolts from

lugs of front fork leg to release brake caliper assembly.

Lift caliper upward to remove from brake disc. Using thru

hole, cable strap caliper to rail of engine guard. Repeat

step to release caliper on opposite side of wheel.

NOTE

Do not operate the front brake hand lever with the front wheel

removed or the caliper pistons may be forced out. Reseating

Front Fender Tip Lamp

pistons requires disassembly of the caliper.

f2212x8x

Jumper Harness [32]

Used on FLHR Only

7.

Insert screwdriver or steel rod through hole in axle on

Figure 2-189. Headlamp Nacelle (FLHRC)

right side of motorcycle. While holding axle stationary,

remove the axle nut, lockwasher and flat washer on the

left side.

9.

With soft mallet, tap axle toward right side of motorcycle

until loose. Pull axle from hub while supporting wheel.

8.

Loosen the two axle holder nuts at bottom of right side

Remove wheel.

fork leg.

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2006 Touring: Chassis

HOME

REAR FENDER

2.34

REMOVAL

f2279x2x

NOTE

For all models except FLHX, begin procedure at step 2 .

1.

On FLHX models, proceed as follows:

a. Remove rear facia. See Section 2.35 REAR FACIA

(FLHX), REMOVAL.

b. Remove rear facia lamp. See Section 2.35 REAR

FACIA (FLHX), REAR FACIA LAMP, REMOVAL.

2.

Place the motorcycle on a hydraulic center stand with

the rear wheel raised off the ground.

3.

Remove seat. See Section 2.25 SEAT, REMOVAL.

4.

Remove rear wheel. See Section 2.4 REAR WHEEL,

Figure 2-191. Rear Fender Front Screw (T40 TORX)

REMOVAL.

5.

Disconnect rear fender lights connector [7] anchored at

f1908x2x

front of rear fender. Release anchor from fender hole.

See Figure 2-190.

6.

Gently pull side cover from frame downtube (no tools

required). Repeat step on opposite side of motorcycle.

7.

Remove four hex screws with lockwashers (two each on

FLHR/C/S and FLTR) to release license plate bracket

from luggage rack.

8.

Obtain ratchet and T40 TORX head bit. Standing on left

side of motorcycle, remove screw to release front of rear

fender from battery box. See Figure 2-191.

Figure 2-192. Rear Bumper Screws (T40 TORX)

9.

At rear of motorcycle, remove inside screw (and flange

nut) to release rear bumper bracket from saddlebag sup-

port bracket and saddlebag support rail. Repeat step on

opposite side of motorcycle. See Figure 2-192.

10.

Reaching under rear bumper, remove flange nut (with

flat washer) to free rear bumper bracket from weld stud

on fender. Remove bumper from motorcycle.

11.

Remove fender side mounting screw located just below

side cover grommet. Repeat step on opposite side of

motorcycle. See Figure 2-193.

12.

Remove upper rear screw from saddlebag support

bracket. Repeat step on opposite side of motorcycle.

See Figure 2-194.

13.

Remove upper front screw from saddlebag support

f2013x8x

bracket. Be aware that rear fender will drop when both

forward screws are removed. Repeat step on opposite

Figure 2-190. Rear Fender Lights Connector [7]

side of motorcycle.

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2006 Touring: Chassis

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LEFT SIDE

FRONT

f1864x2x

f1862x2x

Figure 2-194. Saddlebag Support Bracket Screws

(T40 TORX) - Left Side View

f1991x2x

RIGHT SIDE

2.

Obtain ratchet and T40 TORX head bit. Engaging hole of

fender rear spacer nut, start upper front screw in saddle-

bag support bracket. Repeat step on opposite side of

motorcycle. See Figure 2-194.

3.

Start upper rear screw in saddlebag support bracket.

Repeat step on opposite side of motorcycle.

4.

Standing on left side of motorcycle, start screw securing

front of rear fender to battery box. See Figure 2-191.

5.

Engaging hole in frame and fender front spacer nut, start

fender side mounting screw located just below side

cover grommet. Repeat step on opposite side of motor-

cycle. See Figure 2-193.

Figure 2-193. Fender Side Mounting Screws (T40 TORX)

14. Exercising caution to avoid scratching fender paint on

luggage rack or other bracketry, carefully roll the fender

out. See Figure 2-195. If necessary, have one person

spread the saddlebag support brackets while the fender

is rolled out.

INSTALLATION

1.

Exercising caution to avoid scratching fender paint on

luggage rack or other bracketry, carefully roll the fender

f2014x2x

in. See Figure 2-195. If necessary, have one person

spread the saddlebag support brackets while the other

Figure 2-195. Carefully Roll Out Rear Fender

rolls the fender in.

2006 Touring: Chassis

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HOME

6.

Reaching under rear fender, hang rear bumper bracket

on weld stud. Install flat washer and start flange nut on

f2402x8x

weld stud.

0.25 Inch

(6.35 mm)

7.

Start inside screw (with flange nut) to fasten rear bumper

4

1

bracket to saddlebag support bracket and saddlebag

support rail. Repeat step on opposite side of motorcycle.

See Figure 2-192.

8.

Alternately tighten all rear fender T40 TORX screws to

15-20 ft-lbs (20-27 Nm).

11.

Reaching under rear fender, tighten flange nut on weld

2

stud to 45-85 in-lbs (5.1-9.6 Nm).

9.

Install four hex screws with lockwashers (two each on

8.75 Inches

3

(222.25 mm)

FLHR/C/S and FLTR) to secure license plate bracket to

luggage rack. Alternately tighten screws to 15-20 ft-lbs

(20-27 Nm).

1.

Connector [7B]

3.

Cable Strap

10.

Connect rear fender lights connector

[7] and snap

2.

Conduit

4.

Adhesive Conduit

anchor in rear fender hole. See Figure 2-190.

11.

Align barbed studs in side cover with grommets in frame

Figure 2-196. Install Cable Strap on Conduit

downtubes and push firmly into place

(no tools

required). Repeat step on opposite side of motorcycle.

12.

Install rear wheel. See Section

2.4 REAR WHEEL,

absent, install new cable strap as follows:

INSTALLATION.

a. Adjust conduit so that end is 1/4 inch (6.35 mm) or

13.

Install seat. See Section 2.25 SEAT, INSTALLATION.

less from wire end of connector [7B].

14.

On FLHX models, proceed as follows:

b. Install cable strap 8.75 inches (222.25 mm) from

mating end of connector as shown in Figure 2-196.

a. Install rear facia lamp. See Section

2.35 REAR

FACIA (FLHX), REAR FACIA LAMP, INSTALLA-

Cut any excess cable strap material.

TION.

b. Install rear facia. See Section 2.35 REAR FACIA

CAUTION

(FLHX), INSTALLATION.

Proper placement of the cable strap prevents rearward

movement of the rear fender lights harness. Gradual

accumulation or bunching of the harness rear of the

adhesive conduit can result in damage through contact

REAR FENDER LIGHTS CONDUIT

with rear tire.

2.

Install terminals into socket housing of rear fender lights

connector [94], 6-place Multilock.

REMOVAL

1.

Remove rear fender. See REMOVAL in this section.

Table 8-8. Rear Fender Lights [94]

2.

Remove rear fender lights harness. See Section 8.14

TAIL LAMP ASSEMBLY, REAR FENDER LIGHTS

Chamber

Chamber

Wire Color

Wire Color

HARNESS, REMOVAL

Number

Number

3.

Carefully cut adhesive conduit and remove wire harness.

Orange/White

1

Red/Yellow

4

4.

Remove terminals from socket housing of rear fender

Brown

2

Violet

5

lights connector [94], 6-place Multilock.

Blue

3

Black

6

NOTE

For instructions on properly removing wire terminals, see

NOTE

APPENDIX B.2 MULTILOCK ELECTRICAL CONNECTORS,

For instructions on properly installing wire terminals, see

REMOVING SOCKET/PIN TERMINALS.

APPENDIX B.2 MULTILOCK ELECTRICAL CONNECTORS,

INSTALLING SOCKET/PIN TERMINALS.

3.

Install rear fender lights harness. See Section 8.14 TAIL

INSTALLATION

LAMP ASSEMBLY, REAR FENDER LIGHTS HAR-

NESS, INSTALLATION

1.

Draw rear fender lights harness through new adhesive

conduit until progress is halted by installed cable strap. If

4.

Install rear fender. See INSTALLATION in this section.

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2006 Touring: Chassis

HOME

REAR FENDER CLOISONNE

9740

FLHRS

REMOVAL

1.

Apply 3M GENERAL PURPOSE ADHESIVE REMOVER

(Part No. 051135) to edge of adhesive backing visible

behind cloisonne. Allow to soak.

CAUTION

Avoid excess heat which will damage the painted sur-

face.

2.

Carefully apply heat directly onto cloisonne with ROBIN-

AIR HEAT GUN (HD-25070).

9741

3.

Lift the cloisonne from fender.

FLTR

NOTE

Dental floss can be used to gently saw the heated cloisonne

free of the rear fender.

4.

Remove remaining adhesive with 3M GENERAL PUR-

POSE ADHESIVE REMOVER (Part No. 051135).

INSTALLATION

1.

Peel paper backing off cloisonne.

Figure 2-197. Rear Fender Cloisonne

2.

Place cloisonne into position over recess in rear fender.

NOTE

The cloisonne is centered left to right over the dimpled

recess in the rear fender with the bottom edge of the cloi-

sonne 1.75 inches (44.45 mm) above the bottom edge of the

fender.

3.

Press firmly to affix cloisonne.

2006 Touring: Chassis

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