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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 23

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ICM (CARBURETED)

8.4

REMOVAL

f2375x8x

1.

Remove right side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

2.

Gently pull side cover from frame downtubes (no tools

required).

3.

Disconnect ICM connector [10], 12-place Deutsch. See

Figure 8-6.

4.

Remove two socket screws to detach ICM from electrical

bracket.

INSTALLATION

1.

Align holes in ICM with those in electrical bracket. Install

ICM

two socket screws and tighten to 50-60 in-lbs (5.7-6.8

Connector [10]

Nm).

Figure 8-6. Electrical Bracket (Under Right Side Cover)

2.

Connect ICM connector [10], 12-place Deutsch. See

Figure 8-6.

3.

Align barbed studs in side cover with grommets in frame

4.

Install right side saddlebag. See Section 2.26 SADDLE-

downtubes and push firmly into place

(no tools re-

BAG, INSTALLATION.

quired).

2006 Touring: Electrical

8-7

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SENSORS (CARBURETED)

8.5

MAP SENSOR

6904

Removal

3

1.

Partially remove fuel tank. See Section 4.7 FUEL TANK

1

(CARBURETED), PARTIAL REMOVAL, FLHX, FLHT, or

FLHR/S.

2.

Disconnect MAP sensor connector [80], 3-place Pack-

ard, at top of intake manifold.

3.

Remove T20 TORX screw to release retaining clip from

intake manifold. See Figure 8-7.

4.

Carefully pull pressure port (enveloped in rubber seal)

from hole in intake manifold.

2

1.

T20 TORX Screw

2.

Retaining Clip

5.

If reusing sensor, inspect condition of rubber seal.

3.

MAP Sensor

Replace the seal if it is cut, torn or shows signs of deteri-

oration.

Figure 8-7. Intake Manifold

Installation

3.

Install T20 TORX screw and tighten to 25-35 in-lbs (2.8-

4.0 Nm). See Figure 8-7.

1.

Install rubber seal on pressure port, if removed.

4.

Connect MAP sensor connector [80], 3-place Packard.

2.

With port side down, slide end of retaining clip in slot at

side of sensor. Aligning hole in retaining clip with

5.

Install fuel tank. See Section 4.7 FUEL TANK (CARBU-

threaded hole in intake manifold, carefully press pres-

RETED), INSTALLATION (AFTER PARTIAL REMOVAL),

sure port into bore.

INSTALLATION

(AFTER PARTIAL REMOVAL), or

FLHR/S.

CKP SENSOR

See Section 9.3 SENSORS, CKP SENSOR.

8-8

2006 Touring: Electrical

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IGNITION COIL

8.6

6.

Install fuel tank. For carbureted models, see Section 4.7

REMOVAL

FUEL TANK (CARBURETED), INSTALLATION (AFTER

PARTIAL REMOVAL), INSTALLATION (AFTER PAR-

1.

Partially remove fuel tank. For carbureted models, see

TIAL REMOVAL) or FLHR/S. For fuel injected models,

Section

4.7 FUEL TANK (CARBURETED), PARTIAL

see Section

9.4 FUEL TANK

(FUEL INJECTED),

REMOVAL, FLHX, FLHT or FLHR/S. For fuel injected

INSTALLATION (AFTER PARTIAL REMOVAL), FLHXI,

models, see Section

9.4 FUEL TANK

(FUEL

FLHT/C/U/I, FLTRI or FLHR/C/S/I.

INJECTED), PARTIAL REMOVAL, FLHXI, FLHT/C/U/I,

FLTRI or FLHR/C/S/I.

2.

Unplug spark plug cables from ignition coil towers.

8316

3.

Remove ignition coil connector [83] from left side of igni-

tion coil. See Figure 8-8.

4.

Pull sides of ignition coil bracket outward to remove from

bosses of front fuel tank mount.

5.

Remove two socket screws to free ignition coil from

bracket.

INSTALLATION

1.

Align holes in new ignition coil with holes in bracket.

Properly positioned, connector pin housing should be

positioned at cut in bracket. Install two socket screws

and tighten to 84-144 in-lbs (9.5-16.3 Nm). See Figure

Figure 8-8. Remove Ignition Coil Bracket From Vehicle

8-9.

2.

With the coil towers facing rear of motorcycle, hold igni-

f1925x8x

tion coil and bracket at bottom of frame backbone. Pull

sides of bracket outward and install on bosses of front

fuel tank mount. See Figure 8-8.

3.

Install ignition coil connector [83] onto left side of ignition

coil.

4.

Install spark plug cable to front cylinder onto left side coil

tower. Verify that spark plug cable is captured in double-

sided cable clip at bottom left side of frame backbone.

Install new cable clip on T-stud if damaged or missing.

See Figure 8-11.

To Front

To Rear

5.

Install spark plug cable to rear cylinder onto right side

Cylinder

Cylinder

coil tower. Verify that spark plug cable is captured in two

single-sided cable clips at bottom left side of frame back-

bone. Install new cable clips on T-studs if damaged or

missing. See Figure 8-11.

Figure 8-9. Install Bracket to Ignition Coil

2006 Touring: Electrical

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SPARK PLUGS/SPARK PLUG CABLES

8.7

SPARK PLUGS

NOTE

The number 6R12 plug is supplied as original equipment and

is the only plug that should be used. The resistor plug

reduces radio interference created by the ignition system and

will not adversely affect performance or fuel economy.

REMOVAL

1.

Remove spark plug cables. See SPARK PLUG CABLES

on the next page.

2.

Remove spark plug using a 5/8 inch spark plug socket.

INSPECTION

See Figure 8-10. Examine plugs as soon as they have been

removed. The deposits on the plug base are an indication of

the plug efficiency and are a guide to the general condition of

rings, valves, carburetor and ignition system.

a. A wet black and shiny deposit on plug base, elec-

trodes and ceramic insulator tip indicate an oil

fouled plug. The condition may be caused by worn

Figure 8-10. Types of Plug Base Deposits

rings and pistons, loose valves or seals, weak bat-

tery or faulty ignition.

b. A dry fluffy or sooty black deposit indicates a too

ADJUSTMENT

rich carburetor air-fuel mixture or long periods of

engine idling. Excessive use of the enrichener may

Use only a wire-type gauge. Bend the outside electrode so

also cause this condition.

only a slight drag on the gauge is felt when passing it

c. An overheated plug can be identified by a light

between electrodes. Never make adjustments by bending the

brown, glassy deposit. This condition may be

center electrode. Set gap on all plugs at 0.038-0.043 in.

accompanied by cracks in the insulator or by ero-

(0.97-1.09 mm).

sion of the electrodes. This condition is caused by

too lean an air-fuel mixture, a hot running engine,

valves not seating or improper ignition timing. The

INSTALLATION

glassy deposit on the spark plug is a conductor

when hot and may cause high speed misfiring. A

1.

Before installing spark plugs, check condition of threads

plug with eroded electrodes, heavy deposits or a

in cylinder head and on plug. If necessary soften depos-

cracked insulator should be replaced.

its with penetrating oil and clean out with a thread

chaser.

d. A plug with white, yellow or light tan to rusty brown

powdery deposit indicates balanced combustion.

2.

Apply a very light coating of ANTISEIZE LUBRICANT to

The deposits may be cleaned off at regular intervals

spark plug threads.

if desired.

3.

Install spark plug finger tight and then tighten to 12-

18 ft-lbs (16-24 Nm).

CLEANING

NOTE

1.

Degrease firing end of spark plug using ELECTRICAL

If a torque wrench is not available, finger tighten spark plug

CONTACT CLEANER. Dry spark plug with compressed

and then using a spark plug wrench, tighten plug an addi-

air.

tional 1/4 turn.

2.

Use a thin file to flatten spark plug electrodes. A spark

4.

Connect spark plug cables to spark plug terminals.

plug with sharp edges on its electrodes requires 25%-

Make sure boots/caps are secured properly.

40% less firing voltage than one with rounded edges.

3.

Adjust spark plug gap. See ADJUSTMENT on this page.

5.

Check engine idle speed, and adjust if necessary.

8-10

2006 Touring: Electrical

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2.

Check spark plug cable resistance with an ohmmeter.

SPARK PLUG CABLES

Resistance must be as follows:

NOTE

Table 8-1. Spark Plug Cable Resistance

Resistor-type high-tension cables have a carbon-impreg-

nated fabric core (instead of solid wire) for radio noise sup-

Position

Cable Length

Resistance (Ohms)

pression and improved reliability of electronic components.

Use the exact replacement cable for best results.

Front /Rear

20 Inches (508 mm)

5,000 - 11,666

REMOVAL

3.

Replace cables that are worn or damaged, or that do not

meet resistance specifications.

1WARNING

4.

Check cable boots/caps for cracks or tears. Also check

Never disconnect a spark plug cable with the engine run-

for loose fit on ignition coil and spark plugs. Replace

ning. Doing so will result in an electric shock from the

boots/caps if defects are noted.

ignition system that could result in death or serious

injury.

INSTALLATION

CAUTION

1.

Connect spark plug cables to spark plug terminals.

When disconnecting a spark plug cable from the spark

plug terminal, always grasp and pull on the rubber boot

2.

Install spark plug cable to front cylinder onto left side coil

at the end of the cable assembly (as close to the spark

tower. Verify that spark plug cable is captured in double-

plug terminal as possible). Pulling on the cable portion

sided cable clip at bottom left side of frame backbone.

will damage the carbon core.

Install new cable clip on T-stud if damaged or missing.

See Figure 8-11.

1.

Disconnect spark plug cables from ignition coil and

spark plug terminals.

3.

Install spark plug cable to rear cylinder onto right side

coil tower. Verify that spark plug cable is captured in two

single-sided cable clips at bottom left side of frame back-

INSPECTION

bone. Install new cable clips on T-studs if damaged or

1.

Check cables for cracks or loose terminals.

missing. See Figure 8-11.

8497

2

2

1

1.

Double-Sided Clip

2.

Single-Sided Clip (2)

Figure 8-11. Spark Plug Cable Clips (Left Side View)

2006 Touring: Electrical

8-11

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ALTERNATOR/STATOR

8.8

REMOVAL

f2120x8x

A

1.

Remove seat. See Section 2.25 SEAT, REMOVAL.

1WARNING

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

2.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

3.

Remove the primary chaincase cover. Remove the

clutch, primary chain, compensating sprocket and shaft

extension as a single assembly. See Section 6.5 PRI-

MARY CHAINCASE, REMOVAL, steps 3-15.

B

1CAUTION

The high-output rotor contains powerful magnets. Use

the ROTOR REMOVER/INSTALLER and SHAFT PROTEC-

TOR SLEEVE (HD-41771) to prevent parts damage and

possible hand injury during removal and installation.

4.

Remove the rotor as follows:

a. Verify that threads of engine sprocket shaft are

clean, especially of old Loctite material. See A of

Figure 8-12.

b. Thread the Shaft Protector Sleeve onto the shaft.

C

See B of Figure 8-12.

c. Turn thumbscrews of Rotor Remover/Installer into

threaded holes in rotor face. See C of Figure 8-12.

d. Rotate handle of forcing screw in a clockwise direc-

tion to remove rotor from shaft.

5.

Locate CKP sensor connector [79], 2-place Deutsch,

fixed to bracket at bottom of voltage regulator. Push con-

nector toward right side of motorcycle to disengage

attachment clip from T-stud on bracket. See Figure 8-15.

6.

Loosen locknuts on studs of lower frame crossmember.

Lift voltage regulator and release conduit from P-clip

A Clean Sprocket Shaft Threads.

under left side leg of voltage regulator.

B Install Shaft Protector Sleeve.

7.

Pull away locking latch and remove socket of stator con-

C Install Rotor Remover/Installer.

Rotate Handle in a Clockwise Direction.

nector [46], 3-place Lyall, at bottom left side of voltage

regulator.

Figure 8-12. Remove Rotor from Engine Sprocket Shaft

8-12

2006 Touring: Electrical

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INSTALLATION

1.

From inside crankcase, feed socket and conduit through

hole in crankcase.

2.

Thorougly lubricate grommet with isopropyl alcohol or

glass cleaner. Ribs of grommet must be clean and free

of dirt and oily residue.

3.

Carefully grasp cable stop behind grommet with a nee-

dle nose pliers. Push grommet into crankcase bore while

carefully pulling on outside cable. Installation is com-

plete when cable stop contacts casting and capped rib of

grommet exits crankcase bore.

4.

If necessary, carefully run awl around edge of capped rib

so that it rests flat against seating surface on crankcase.

f2416x8x

CAUTION

Stator

Do not reuse T27 TORX screws. The threads of the

Connector [46]

screws contain a locking compound in pellet form. When

the screw is started, the pellet breaks releasing the com-

Figure 8-13. Voltage Regulator (Left Side View)

pound.

5.

Install four new T27 TORX screws to fasten stator to

crankcase. Alternately tighten screws to 55-75 in-lbs

NOTE

(6.2-8.5 Nm).

The rubber molded stator connector is not serviceable. Dam-

age to terminals or molding requires stator and/or voltage

1CAUTION

regulator replacement.

The high-output rotor contains powerful magnets. Use

8.

Draw stator conduit and socket to rear of front engine

the ROTOR REMOVER/INSTALLER and SHAFT PROTEC-

stabilizer link and then up to area in front of primary

TOR SLEEVE (HD-41771) to prevent parts damage and

chaincase.

possible hand injury during removal and installation.

9.

Remove four T27 TORX screws to free stator from

crankcase. Discard screws.

10. Using point of awl, carefully lift capped rib on grommet

2

4

away from crankcase and then insert into bore between

grommet and casting. See Figure 8-14. Tilt awl slightly

squirting isopropyl alcohol or glass cleaner into opening.

Repeat this step at one or two other locations around

grommet.

11. While pushing on capped rib from outside of crankcase,

draw grommet through bore by pulling on cable stop with

needle nose pliers. Rock grommet back and forth to

facilitate removal, if necessary. Exercise caution to avoid

damaging ribs on grommet if stator is to be reused.

12. Draw conduit and socket through crankcase bore.

CLEANING AND INSPECTION

1

3

f2415x8x

1.

Check inside of rotor and remove any metal fragments

captured by magnets.

1.

Awl

3.

Opening

2.

Clean the rotor using a petroleum solvent. Clean the sta-

2.

Capped Rib

4.

Stator

tor and grommet by wiping it with a clean cloth.

Figure 8-14. Remove Grommet From Crankcase

2006 Touring: Electrical

8-13

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VOLTAGE REGULATOR

8.9

REMOVAL

f2417x8x

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

2

MAXI-FUSE, REMOVAL.

3

2.

Locate CKP sensor connector [79], 2-place Deutsch,

fixed to bracket at bottom of voltage regulator. Push con-

nector toward right side of motorcycle to disengage

attachment clip from T-stud on bracket. See Figure 8-15.

3.

Remove locknuts from studs on lower frame crossmem-

ber. Lift voltage regulator off studs.

4.

Release conduit and convoluted tubing from P-clips

1

under left and right side legs of voltage regulator. Allow

4

voltage regulator to hang upside down at front of lower

frame crossmember. See Figure 8-16.

1.

Stator Connector [46A]

5.

Pull away locking latch and remove socket of voltage

2.

Voltage Regulator Connector [77A]

regulator connector [77], 2-place Lyall, at bottom right

3.

Locking Latch

side of voltage regulator.

4.

CKP Sensor Connector [79] Bracket/T-Stud

6.

Pull away locking latch and remove socket of stator con-

nector [46], 3-place Lyall, at bottom left side of voltage

Figure 8-16. Voltage Regulator (Bottom View)

regulator.

NOTE

7.

Remove voltage regulator from motorcycle.

The rubber molded voltage regulator and stator connectors

are not serviceable. Damage to terminals, molding or locking

latches requires voltage regulator and/or stator replacement.

INSTALLATION

f2416x8x

1.

Position voltage regulator upside down at front of lower

frame crossmember. See Figure 8-16.

2.

Install socket of stator connector [46], 3-place Lyall, at

bottom left side of voltage regulator. Push against lock-

ing latch until socket is fully engaged.

3.

Install socket of voltage regulator connector [77], 2-place

Lyall, at bottom right side of voltage regulator. Push

against locking latch until socket is fully engaged.

4.

Turning voltage regulator right side up, start onto studs

on lower frame crossmember.

5.

Capture stator connector conduit in left side P-clip. Cap-

ture voltage regulator connector conduit and CKP sen-

[77]

[79]

sor connector convoluted tubing in right side P-clip. See

Figure 8-15. Remove slack to ensure that stator conduit

[46] Stator

[46]

and CKP sensor tubing does not contact front engine

[77] Voltage Regulator

stabilizer link.

[79] CKP Sensor

6.

Install locknuts on studs and alternately tighten to 70-

Figure 8-15.

Voltage Regulator (Left Side View)

100 in-lbs (7.9-11.3 Nm).

2006 Touring: Electrical

8-15

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BATTERY

8.10

GENERAL

Warning

Label

All batteries are permanently sealed, maintenance-free,

valve-regulated, lead/calcium and sulfuric acid batteries. The

batteries are shipped pre-charged and ready to be put into

service. Do not attempt to open these batteries for any rea-

son.

1WARNING

All batteries contain electrolyte. Electrolyte is a sulfuric

acid solution that is highly corrosive and can cause

severe chemical burns. Avoid contact with skin, eyes,

and clothing. Avoid spillage. Always wear protective face

shield, rubberized gloves and protective clothing when

f1730x8x

working with batteries. A warning label is attached to the

top of the battery. See Figure 8-17. Never remove warn-

Figure 8-17. Maintenance-Free Battery

ing label from battery. Failure to read and understand all

precautions contained in warning label before perform-

ing any service on batteries could result in death or seri-

BATTERY TESTS

ous injury. See Figure 8-18.

Three different procedures may be performed to provide a

good indicator of battery condition: a voltmeter test, a con-

Table 8-2. Antidote

ductance test, or a load test.

A battery may be tested, whether fully charged or not, via the

External -

Flush with water

voltmeter or conductance tests. In order to perform a load

test, however, the battery must be fully charged.

Internal -

Drink large quantities of milk or

water, followed by milk of magne-

sia, vegetable oil or beaten eggs.

VOLTMETER TEST

Call doctor immediately.

See Table 8-3. Check the voltage of the battery to verify that

it is in a 100% fully charged condition. If the open circuit (dis-

Eyes -

Flush with water, get immediate

connected) voltage reading is below 12.6V, charge the bat-

medical attention.

tery and then recheck the voltage after the battery has set for

Contents

Wear

Contents

Keep

Read

Keep Away

are Corrosive. Safety Glasses. are Explosive.

Flames Away.

Instructions.

From Children.

f2396x8x

Figure 8-18. Battery Warning Label

2006 Touring: Electrical

8-17

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one to two hours. If the voltage reading is 12.7V or above,

perform the LOAD TEST described on this page.

Table 8-3. Voltmeter Test

Voltage (OCV)

State of Charge

12.7

100%

12.6

75%

12.3

50%

12.0

25%

11.8

0%

CONDUCTANCE TEST

x0661x3x

Test battery using the ADVANCED BATTERY CONDUC-

TANCE AND ELECTRICAL SYSTEM ANALYZER (HD-

48053). See Figure 8-19. Proceed as follows:

Figure 8-20. Battery Test Results-Printout

1.

Connect the analyzer leads to the battery.

NOTE

2.

Follow the instructions in the analyzer instruction manual

to perform a battery test.

A REPLACE BATTERY test result may also mean a poor

connection between the battery cables and the motorcycle.

The test results will include a decision on the battery condi-

After disconnecting the battery cables from the battery, retest

tion, the measured state of charge and the measured CCA.

the battery using the out-of-vehicle test before replacing.

See Figure 8-20. The analyzer printer will provide you with a

printout including one of five possible test results:

● GOOD BATTERY-return the battery to service.

LOAD TEST

● GOOD-RECHARGE-fully charge the battery and return

The load test measures battery performance under full cur-

to service.

rent load. To load test the battery, proceed as follows:

● CHARGE & RETEST-Fully charge the battery and

1.

Remove the battery from the motorcycle. See DISCON-

retest.

NECTION AND REMOVAL in this section.

● REPLACE BATTERY-replace the battery and retest.

● BAD CELL-REPLACE-replace the battery and retest.

CAUTION

Load testing a discharged battery can result in perma-

nent battery damage.

HD-48053

2.

Always fully charge the battery before testing or test

readings will be incorrect. See CHARGING BATTERY, in

this section. Load testing a discharged battery can also

result in permanent battery damage.

3.

After charging, allow battery to stand for at least one

hour before testing.

1WARNING

Always turn the battery load tester OFF before connect-

ing the tester cables to the battery terminals. Connecting

tester cables with the load tester ON could cause a spark

resulting in a battery explosion. A battery explosion may

rupture the battery case causing a discharge or spray of

Figure 8-19. Advanced Battery Conductance and

sulfuric acid which could result in death or serious

Electrical System Analyzer (Part No. HD-48053)

injury.

8-18

2006 Touring: Electrical

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6.

Install the battery on the motorcycle. See INSTALLA-

TION AND CONNECTION in this section.

Load

Tester

DISCONNECTION AND REMOVAL

1.

Remove seat. See Section 2.25 SEAT, REMOVAL.

1WARNING

Always disconnect the negative battery cable first. If the

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion which could result in death or serious injury.

Induction

Pickup

2.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

3.

Unthread bolt and remove battery positive cable (red)

from battery positive (+) terminal.

4.

Loosen T40 TORX screw to move lip of hold-down clamp

off edge of battery. Remove battery from battery box.

f1731x8x

CLEANING AND INSPECTION

Figure 8-21. Load Test Battery

1.

Battery top must be clean and dry. Dirt and electrolyte

on top of the battery can cause battery to self-discharge.

Clean battery top with a solution of baking soda (sodium

4.

Connect tester leads to battery posts and place induc-

bicarbonate) and water (5 teaspoons baking soda per

tion pickup over negative (black) cable. See Figure 8-21.

quart or liter of water). When the solution stops bubbling,

rinse off the battery with clean water.

2.

Clean cable connectors and battery terminals using a

CAUTION

wire brush or sandpaper. Remove any oxidation.

To avoid load tester and/or battery damage, do not leave

3.

Inspect the battery screws, clamps and cables for break-

the load tester switch turned ON for more than 20 sec-

age, loose connections and corrosion. Clean clamps.

onds.

4.

Check the battery posts for melting or damage caused

5.

Referencing Table 8-4, load battery at 50% of CCA rat-

by overtightening.

ing using the load tester. Voltage reading after 15 sec-

5.

Inspect the battery for discoloration, raised top or a

onds should be 9.6V or more at 70°F. (21°C).

warped or distorted case, which might indicate that the

battery has been frozen, overheated or overcharged.

Table 8-4. Battery Load Test

6.

Inspect the battery case for cracks or leaks.

COLD CRANKING

100%

50%

AMPERAGE (CCA)

BATTERY CHARGING

TOURING

300

150

SAFETY PRECAUTIONS

1WARNING

Never charge a battery without first reviewing the instructions

for the charger being used. In addition to the manufacturer’s

Always turn the battery load tester OFF before discon-

instructions, follow these general safety precautions:

necting the tester cables from the battery terminals. Dis-

connecting tester cables with the load tester ON could

● Always wear proper eye, face and hand protection.

cause a spark resulting in a battery explosion. A battery

● Always charge batteries in a well-ventilated area.

explosion may rupture the battery case causing a dis-

charge or spray of sulfuric acid which could result in

● Turn the charger “OFF” before connecting the leads

death or serious injury.

to the battery to avoid dangerous sparks.

2006 Touring: Electrical

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HOME

Table 8-5. Battery Charging Rates/Estimated Times

State of Charge

Battery

3

6

10

20

Amp-Hour

Amp Charger

Amp Charger

Amp Charger

Amp Charger

Voltage Reading

% of Charge

12.7 V

100%

-

-

-

-

12.6 V

75%

2.5 hours

1.25 hours

45 minutes

25 minutes

TOURING

12.3 V

50%

5 hours

2.5 hours

1.5 hours

50 minutes

28

12.0 V

25%

7.5 hours

3.75 hours

2.25 hours

70 minutes

11.8 V

0%

10 hours

5 hours

3 hours

1.5 hours

The figures listed above assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter

charging time. If colder, use a slightly longer charging time.

The use of constant current chargers to charge sealed maintenance-free batteries is not recommended. Any overcharge will cause dry-

out and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed above and

do not continue charging the battery if it gets hot. When charging, never exceed 15 volts for more than 30 minutes.

● Never try to charge a visibly damaged or frozen bat-

tery.

CAUTION

● Connect the charger leads to the battery; red posi-

If the battery releases an excessive amount of gas dur-

tive (+) lead to the positive (+) terminal and black

ing charging, decrease the charging rate. If the battery

negative (-) lead to the negative (-) terminal. If the

gets hotter than 110˚F. (43˚C) during charging, discon-

battery is still in the motorcycle, connect the nega-

tinue charging and allow the battery to cool. Overheating

tive lead to the chassis ground. Be sure that the igni-

may result in plate distortion, internal shorting, dryout or

tion and all electrical accessories are turned off.

other damage.

● Make sure that the charger leads to the battery are

1.

Perform a voltmeter test to determine the state of

not broken, frayed or loose.

charge. See VOLTMETER TEST in this section. If bat-

tery needs to be charged, proceed to step 2.

● If the battery becomes hot, or if violent gassing or

spewing of electrolyte occurs, reduce the charging

CAUTION

rate or turn off the charger temporarily.

Always remove the battery from the motorcycle before

● Always turn the charger “OFF” before removing

charging. Accidental electrolyte leakage will damage

charger leads from the battery to avoid dangerous

motorcycle parts.

sparks.

2.

Remove the battery from the motorcycle. See DISCON-

NECTION AND REMOVAL in this section. Place the bat-

tery on a level surface.

CHARGING BATTERY

Charge the battery if any of the following conditions exist:

1WARNING

Always unplug or turn OFF the battery charger before

● Motorcycle lights appear dim.

connecting the charger clamps to the battery. Connect-

● Electric starter sounds weak.

ing clamps with the charger ON could cause a spark

● Battery has not been used for an extended period of

resulting in a battery explosion. A battery explosion may

time.

rupture the battery case causing a discharge or spray of

sulfuric acid which could result in death or serious

1WARNING

injury.

Always charge the battery in a well ventilated area.

CAUTION

Explosive hydrogen gas escapes from the battery during

charging. Keep open flames, electrical sparks and smok-

Do not reverse the charger connections described in the

ing materials away from the battery at all times. Failure

following steps or the charging system of the motorcycle

to do so could result in death or serious injury.

could be damaged.

8-20

2006 Touring: Electrical

HOME

3.

Connect the red battery charger lead to the positive (+)

INSTALLATION AND CONNECTION

terminal of the battery.

4.

Connect the black battery charger lead to the negative

1.

Place the fully charged battery into the battery box, ter-

(-) terminal of the battery.

minal side forward.

NOTE

If the battery is still in the motorcycle, connect the negative

CAUTION

lead to the chassis ground. Be sure that the ignition and all

Connect the cables to the correct battery terminals or

electrical accessories are turned off.

damage to the motorcycle electrical system will occur.

5.

Step away from the battery and turn on the charger. See

the charging instructions in Table 8-5.

1WARNING

1WARNING

Always connect the positive battery cable first. If the

positive cable should contact ground with the negative

Always unplug or turn OFF the battery charger before

cable installed, the resulting sparks may cause a battery

disconnecting the charger clamps from the battery. Dis-

explosion which could result in death or serious injury.

connecting clamps with the charger ON could cause a

spark resulting in a battery explosion. A battery explo-

sion may rupture the battery case causing a discharge

CAUTION

or spray of sulfuric acid which could result in death or

serious injury.

Overtightening bolts can damage battery terminals.

6.

After the battery is fully charged, disconnect the black

1.

Insert bolt through battery positive

cable

(red) into

battery charger lead to the negative (-) terminal of the

threaded hole of battery positive (+)

terminal. Tighten

battery.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

7.

Disconnect the red battery charger lead to the positive

(+) terminal of the battery.

8.

Mark the charging date on the battery.

f2268x8x

Frame Hole

Frame

9.

Perform CONDUCTANCE TEST or LOAD TEST to

Cruise Cable

Cross Member

Routing Only

determine the condition of the battery.

NOTE

If charging battery because voltmeter test reading was below

12.6V, recheck the voltage after the battery has set for one to

two hours. If the voltage reading is 12.7V or above, perform

the LOAD TEST.

Positive

Battery Cable

BATTERY CABLE ROUTING

1WARNING

Hole on left side of frame crossmember is used for

Negative

cruise cable routing only. Use of the hole for battery

Battery Cable

cable routing can result in contact with hot exhaust pipe

causing melting or burning of the cable insulation, dam-

age that can lead to driveability problems or fire hazard,

conditions which could result in death or serious injury.

Main Power

To Maxi-Fuse

Route all battery cables through opening between tray of bat-

tery box and bottom of frame cross member. Cables should

Figure 8-22. Battery Cable Routing (Right Side View)

be positioned as shown in Figure 8-22.

2006 Touring: Electrical

8-21

HOME

2.

Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten

f1732x8x

bolt to 60-96 in-lbs (6.8-10.9 Nm).

Effect of Temperature on

Battery Self-Discharge Rate

3.

Apply a light coat of petroleum jelly or ELECTRICAL

CONTACT LUBRICANT, Part No. 99861-02 (1 oz tube),

100 %

C

to both battery terminals.

A

P

at 77°F

A

4.

Rotate the hold-down clamp so that the lip (with rubber

75 %

C

at 105°F

I

pad) rests on the edge of the battery. Tighten T40 TORX

T

Y

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

50 %

MONTHS OF STAND

5.

Install seat. See Section 2.25 SEAT, INSTALLATION.

0

3

6

9

12

15

Figure 8-23. Battery Self-Discharge Rate

STORAGE

Charge the battery every month if stored at temperatures

1WARNING

below 60˚ F. (16˚ C). Charge the battery more frequently if

stored in a warm area above 60˚ F. (16˚ C).

Store the battery out of the reach of children. Inadequate

safety precautions could result in death or serious

NOTE

injury.

The GLOBAL BATTERY CHARGER (Part No. 99863-01)

may be used to maintain battery charge for extended periods

CAUTION

of time without risk of overcharging or boiling.

The electrolyte in a discharged battery will freeze if

When returning a battery to service after storage, refer to the

exposed to freezing temperatures. Freezing may crack

instructions under CHARGING BATTERY in this section.

the battery case and buckle battery plates.

If the motorcycle will not be operated for several months,

such as during the winter season, remove the battery from

the motorcycle and fully charge. See CHARGING BATTERY

in this section.

Self-discharge is a normal condition and occurs continuously

at a rate that depends on the ambient temperature and the

battery’s state of charge. Batteries discharge at a faster rate

at higher ambient temperatures. To reduce the self-discharge

rate, store battery in a cool (not freezing), dry place. See Fig-

ure 8-23.

8-22

2006 Touring: Electrical

HOME

HEADLAMP (FLHR/C/S, FLHX, FLHT/C/U)

8.11

HEADLAMP ASSEMBLY

Wireform

Loop

REMOVAL

1.

Remove Phillips screw at bottom of headlamp door

(chrome ring). Remove headlamp door.

2.

Proceed as follows:

FLHX, FLHT/C/U: Remove three Phillips screws from

retaining ring and carefully pull headlamp assembly from

outer fairing. See Figure 8-24.

FLHR/C/S: Remove seven Phillips screws from head-

lamp housing and carefully pull headlamp assembly

from headlamp nacelle.

Retainer

3.

Remove headlamp connector [38] at back of headlamp

bulb. Remove headlamp assembly from motorcycle.

f2343x8x

Figure 8-25. Headlamp Bulb Assembly

INSTALLATION

1.

Install headlamp connector [38] at back of headlamp

FLHR/C/S: Align holes in headlamp housing with well-

bulb.

nuts in headlamp nacelle (headlamp door bracket at bot-

2.

Proceed as follows:

tom). Install seven Phillips screws and alternately

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

FLHX, FLHT/C/U: Align holes in retaining ring of head-

lamp assembly with those in outer fairing (headlamp

3.

Fit the square-shaped portion of the headlamp door

door bracket at bottom). Install three Phillips screws and

spring into slot at top of headlamp housing and then

alternately tighten to 23-28 in-lbs (2.6-3.2 Nm). See Fig-

snap the headlamp door (chrome ring) into place. Install

ure 8-24.

Phillips screw at bottom of headlamp door and tighten to

9-18 in-lbs (1.0-2.0 Nm).

9464

1

HEADLAMP BULB REPLACEMENT

The headlamp is a replaceable bulb (and not a sealed

beam). Made of quartz glass filled with Halogen gas, the bulb

is very delicate and must be handled with care.

NOTE

When replacement is required, use only the specified bulb

available from your Harley-Davidson dealer. Improper watt-

age or bulb may cause charging system problems.

2

1.

Remove headlamp. See HEADLAMP ASSEMBLY,

REMOVAL.

3

2.

Remove rubber boot at back of lense.

3.

Press down on wireform loop and push pin end out from

Figure 8-24. Remove Retaining Ring Screws

under lip of retainer to release. See Figure 8-25. Use

(FLHX, FLHT/C/U Model Shown)

hinge to swing wireform out of the way.

2006 Touring: Electrical

8-23

HOME

f1285b2x

A

A

25 ft.

(7.62m)

Figure 8-26. Check Headlamp Alignment

NOTE

7.

Install rubber boot at back of lense.

If it is difficult to free pin end of wireform from under lip of

8.

Install headlamp. See HEADLAMP ASSEMBLY,

retainer, loosen retainer screw 1/2-1 turn and then repeat

INSTALLATION.

step 3.

1WARNING

The bulb contains Halogen gas under pressure. Wear

HEADLAMP ADJUSTMENT

adequate eye protection and handle the bulb carefully.

Inadequate safety precautions could result in death or

Check headlamp beam for proper height and lateral align-

serious injury.

ment.

4.

Remove and discard bulb.

1WARNING

CAUTION

DO NOT modify the ignition/light key switch wiring to

Never touch the quartz bulb with your fingers. Finger-

disable the automatic-on headlamp feature. High visibil-

prints will etch the glass and cause premature bulb fail-

ity is an important safety consideration for motorcycle

ure. Always wrap the bulb in paper or a clean dry cloth

riders. Ensure that the headlamp is on at all times. Fail-

during handling.

ure to do so could result in death or serious injury.

5.

Install new bulb in lense. Rotate bulb as necessary so

1.

Verify correct front and rear tire inflation pressure.

that wider ear on backplate points toward the top of the

headlamp assembly.

2.

Place the motorcycle on a level floor or pavement in an

NOTE

area with minimum light.

The top of the headlamp assembly can be determined by the

3.

See Figure 8-26. Point the front of the motorcycle toward

orientation of the decorative logo on the opposite side, or the

a screen or wall which is 25 feet (7.62 m) from where

location of the headlamp door bracket, which is always at the

patch of front tire contacts floor (i.e. - directly below front

bottom of the assembly.

axle).

6.

Use hinge to rotate wireform over socket at back of bulb.

4.

Draw a horizontal line on screen or wall that is exactly

Press down on loop and push pin end under lip of

the same height above the floor as the headlamp center.

retainer to secure. See Figure 8-25.

5.

Have a person whose weight is roughly the same as that

NOTE

of the principal rider sit on the motorcycle seat. The

If retainer screw was loosened to release wireform, use fin-

weight of the rider will compress the vehicle suspension

ger to hold retainer in place and then slowly tighten screw

slightly.

until snug. Turning headlamp assembly over, verify that

6.

Stand the motorcycle upright with both tires resting on

reflector cone is still centered under decorative logo. If it is

the floor and with the front wheel held in straight align-

not, loosen retainer screw and repeat step until the proper

ment (directly forward).

results are achieved.

8-24

2006 Touring: Electrical

HOME

NOTE

9463

2

The headlamp adjustment can be performed without remov-

1

ing the headlamp door (chrome ring).

10. If the headlamp alignment requires adjustment, use

adjuster slots in headlamp door to insert Phillips screw-

driver between headlamp housing and rubber gasket.

See upper frame of Figure 8-27.

Turn the vertical adjuster screw as necessary to adjust

the headlamp vertically. Turn the horizontal adjuster

2

screw to adjust the headlamp horizontally. See lower

frame of Figure 8-27.

9464

3

4

Headlamp Door Removed for Illustration Purposes

1.

Headlamp Door

2.

Adjuster Slot (2)

3.

Vertical Adjuster Screw

4.

Horizontal Adjuster Screw

Figure 8-27. Adjust Headlamp Alignment

(FLHX, FLHT/C/U Model Shown)

7.

Turn the Ignition/Light Key Switch to IGNITION. Set the

Light Switch on the left handlebar to Hi(gh) beam.

8.

Check the light beam for proper height alignment. The

center of the main beam of light should be even with the

horizontal line on the screen or wall.

9.

Check the light beam for proper lateral alignment. The

main beam of light should be directed straight ahead

(i.e., equal area of light to right and left of center).

2006 Touring: Electrical

8-25

HOME

HEADLAMP (FLTR)

8.12

HEADLAMP ASSEMBLY

Plastic

Bulb

Retainer

Housing

REMOVAL

1.

Remove the outer fairing. See Section 2.31 UPPER

FAIRING/WINDSHIELD

(FLTR), OUTER FAIRING,

REMOVAL.

2.

Move outer fairing assembly to bench area.

3.

Squeeze two external tabs to disconnect headlamp har-

ness connectors from bulb contacts.

CAUTION

Wrap electrical tape around blade of screwdriver to pre-

vent damage to tabs of transparent lense cover.

4.

From inboard side of outer fairing, release top of trans-

parent lense cover from slots in fairing by gently

depressing two tabs with blade of screwdriver. Depress

two bottom tabs and remove lense cover from fairing.

f1546x8x

Figure 8-29. Remove Retainer to Release Bulb

f1544x8x

4

3

5.

Remove plastic protective sleeve from top center hex

adjuster stud. See inset of Figure 8-28.

6.

Depress mounting clips on all three hex adjuster studs

and pull headlamp assembly out front of outer fairing.

See Figure 8-28.

INSTALLATION

1.

At front of outer fairing, align ends of hex adjuster studs

with holes in plastic bosses. Push headlamp assembly

into position until mounting clips engage outer fairing.

1

CAUTION

To avoid cutting or chafing wires, be sure to install plas-

2

tic protective sleeve on top center stud of headlamp

assembly. See inset of Figure 8-28.

2.

Carefully snap bottom tabs of transparent lense cover

into bottom slots of outer fairing. Carefully snap upper

tabs of lense cover into upper slots of fairing.

f2284x8x

3.

Install headlamp harness connectors onto bulb contacts.

1.

Plastic Protective Sleeve

3.

Hex Adjuster Stud

4.

Install the outer fairing. See Section 2.31 UPPER FAIR-

2.

Mounting Clip

4.

Plastic Boss

ING/WINDSHIELD (FLTR), OUTER FAIRING, INSTAL-

LATION.

Figure 8-28. Depress Mounting Clips

8-26

2006 Touring: Electrical

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