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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 24

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HEADLAMP BULB REPLACEMENT

f1545x8x

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.

1

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

REMOVAL

1.

Remove the outer fairing. See Section 2.31 UPPER

3

FAIRING/WINDSHIELD

(FLTR), OUTER FAIRING,

REMOVAL.

1.

Wider Ear

2.

Slot

3.

Tabs

2.

Move outer fairing assembly to bench area.

3.

Squeeze two external tabs to disconnect headlamp har-

Figure 8-30. Install New Bulb in Bulb Housing

ness connector from bulb contacts.

4.

Remove rubber boot at back of bulb housing.

3.

Install rubber boot over retainer until flush with base of

5.

Rotate plastic retainer in a counter-clockwise direction to

bulb socket.

remove from bulb housing flange. See Figure 8-29.

4.

Connect headlamp harness connector to bulb contacts.

5.

Install the outer fairing. See Section 2.31 UPPER FAIR-

1WARNING

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

LATION.

The bulb contains Halogen gas under pressure. Wear

adequate eye protection and handle the bulb carefully.

Inadequate safety precautions could result in death or

serious injury.

HEADLAMP ADJUSTMENT

6.

Remove and discard bulb.

Check headlamp beam for proper height and lateral align-

ment. Proceed as follows:

INSTALLATION

1WARNING

DO NOT modify the ignition/light key switch wiring to

CAUTION

disable the automatic-on headlamp feature. High visibil-

ity is an important safety consideration for motorcycle

Never touch the quartz bulb with your fingers. Finger-

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

prints will etch the glass and cause premature bulb fail-

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

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

during handling.

1.

Verify correct front and rear tire inflation pressure.

2.

Place the motorcycle on a level floor or pavement in an

1.

Install new bulb in bulb housing. Orient bulb so that

area with minimum light.

wider ear on backplate is topside and then push bottom

3.

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

of backplate so that tabs on outboard side fit snugly in

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

slot of bulb housing. See Figure 8-30.

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

2.

Place plastic retainer over bulb housing flange and

axle).

rotate in a clockwise direction until tight. See Figure 8-

4.

Draw a horizontal line on screen or wall that is exactly

29.

the same height above the floor as the headlamp center.

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6421

6420

LEFT SIDE

RIGHT SIDE

Figure 8-31. Roatate Hex Adjusters to Adjust Headlamp (FLTR)

5.

Have a person whose weight is roughly the same as that

11. Using a deepwell 4.5 mm with 1/4 inch drive socket

of the principal rider sit on the motorcycle seat. The

(Snap-On STMM4.5) and flexible driver

(Snap-On

weight of the rider will compress the vehicle suspension

TM62B), adjust the headlamp horizontally by turning

slightly.

either the left or right side adjuster. Turn both adjusters

equally to adjust the headlamp vertically.

6.

Stand the motorcycle upright with both tires resting on

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

NOTE

ment (directly forward).

If the socket does not easily fit the adjuster, see if a deepwell

7.

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

3/16 inch with 1/4 inch drive socket (Snap-On STM6) pro-

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

duces better results.

8.

Check the light beam for proper height alignment. The

Adjuster rotation moves the headlamp beam as follows:

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

horizontal line on the screen or wall.

Table 8-6. FLTR Hex Adjuster Rotation

9.

Check the light beam for proper lateral alignment. The

main beam of light should be directed straight ahead

Beam

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

Hex Adjuster

Rotation

Movement

10.

Locate the hex adjusters near the bottom edge of the

Left Only

CW

inner fairing. See Figure

8-31. Turning the adjusters

To the Right

causes the double headlamp housing to pivot around its

Right Only

CCW

upper mount.

Left Only

CCW

To the Left

Right Only

CW

Left and Right Equally

CW

Upward

Left and Right Equally

CCW

Downward

CW= Clockwise

CCW= Counter-Clockwise

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AUXILIARY LAMPS

8.13

AUXILIARY LAMP BULB

Lamp

Index Tab

REMOVAL

1.

Loosen auxiliary lamp door screw as required to pull

lamp door from lip of lamp housing. See Figure 8-32.

2.

Disconnect auxiliary lamp connector [199L/R], 2-place

Packard. See Figure 8-33.

3.

Remove nesting ring at back of lense.

1WARNING

Nesting Ring

The bulb contains Halogen gas under pressure. Wear

9299

Index Tab

adequate eye protection and handle the bulb carefully.

Inadequate safety precautions could result in death or

serious injury.

Figure 8-33. Auxiliary Lamp Assembly

4.

Rotate bulb/pin housing 1/4 turn in a counterclockwise

direction and remove from lense. Discard bulb/pin hous-

ing. See Figure 8-34.

9462

1

2

9295

3

Figure 8-34. Auxiliary Lamp Bulb/Pin Housing

4

CAUTION

Never touch the quartz bulb with your fingers. Finger-

5

prints will etch the glass and cause premature bulb fail-

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

during handling.

5.

Install new bulb/pin housing in lense and rotate 1/4 turn

6

in a clockwise direction. See Figure 8-34.

INSTALLATION

1.

Auxiliary Lamp

4.

Allen Head Screw (2)

1.

Place nesting ring at back of lense with the concave side

2.

Door

5.

Mounting Bracket

up. See Figure 8-33.

3.

Door Screw

6.

Turn Signal Lamp

2.

Connect auxiliary lamp connector

[199L/R],

2-place

Figure 8-32. Auxiliary and Front Turn Signal Lamp

Packard. See Figure 8-33.

2006 Touring: Electrical

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5.

Install lamp door over lip of lamp housing. Rotate lamp

[31R]

[31L]

door so that screw is centered at bottom, and then

tighten door screw until snug.

AUXILIARY LAMP HOUSING

REMOVAL

NOTE

If replacing only the lamp housing, begin at step 1. Start at

step 2 if replacing the entire lamp assembly

1.

Disassemble auxiliary lamp if not replacing the entire

assembly, if necessary. See AUXILIARY LAMP BULB,

REMOVAL, in this section, steps 1-3. See Figure 8-37.

2.

Proceed as follows: FLHT/C/U: Remove outer fairing.

See Section

2.30 UPPER FAIRING/WINDSHIELD

f2356x8x

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

REMOVAL. Locate the left or right front turn signal/auxil-

iary lamp connector [31L/R], 4-place Multilock, on T-stud

at top of left or right fairing support brace

(outboard

[31L] Left Front Turn Signal/Auxiliary Lamp

side). See Figure 8-35.

[31R] Right Front Turn Signal/Auxiliary Lamp

FLHR/C: Remove headlamp assembly. See Section

Figure 8-35. Inner Fairing (FLHT/C/U)

8.11 HEADLAMP

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

HEADLAMP ASSEMBLY, REMOVAL. Locate auxiliary

lamps connector [73], white 2-place Multilock. See Fig-

f2212x8x

ure 8-36.

3.

Disconnect front turn signal/auxiliary lamp connector.

4.

Remove appropriate terminal(s) from socket housing.

Table 8-7. Auxiliary Lamps

FLHT/C/U [31L/R], 4-Place

Left Side [31L]

Right Side [31R]

Wire Color

Chamber

Wire Color

Chamber

Gray/Black

4

Gray/Black

4

NOTE: Terminals 1, 2 and 3 are reserved for the turn signal lamp.

FLHR/C [73], 2-Place

Auxiliary Lamps

Auxiliary Lamps

Switch Connector [109]

Connector [73]

Left Side

Right Side

Wire Color

Chamber

Wire Color

Chamber

Figure 8-36. Headlamp Nacelle (FLHRC)

Gray/Black

1

Gray/Black

2

NOTE

3.

Place nesting ring over edge of lamp housing. Rotate

nesting ring until index tab engages slot at bottom of

For instructions on removing terminals, see APPENDIX B.2

lamp housing.

MULTILOCK ELECTRICAL CONNECTORS, REMOVING

SOCKET/PIN TERMINALS.

4.

Holding nesting ring in place, rotate lense so that index

5.

Remove two allen head screws to release turn signal

tabs at back engage slots in nesting ring.

lamp from mounting bracket. See Figure 8-32.

8-30

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10. Remove auxiliary lamp (with Belleville washer and swivel

block) from the auxiliary lamp bracket.

INSTALLATION

1.

Lay old auxiliary lamp next to new auxiliary lamp and cut

wire to length.

2.

Strip 3/16 inch (4.8 mm) of insulation off wire and crimp

on new socket terminal.

NOTE

For instructions on crimping terminals, see APPENDIX B.2

MULTILOCK ELECTRICAL CONNECTORS, CRIMPING

INSTRUCTIONS.

9366

3.

If removed, slide swivel block and Belleville washer down

Figure 8-37. Auxiliary Lamp Housing

wire onto auxiliary lamp stud. Be sure that rounded side

of swivel block and concave side of Belleville washer

face auxiliary lamp.

Mechanics Wire

4.

Feed wire through slot at top of auxiliary lamp bracket

and insert threaded stud into forward slot. Slide clamp

block (rounded side up), turn signal mounting bracket

and locknut up wire onto auxiliary lamp stud at bottom of

bracket.

5.

Using flare nut socket (Snap-on® FRX181), tighten lock-

nut to 18 ft-lbs (24.4 Nm).

6.

Reattach mechanics wire to socket terminal and care-

fully pull end of mechanics wire to draw socket terminal

back through conduit.

Socket Terminal

7.

Carefully remove mechanics wire to avoid damage to

terminal.

f1418x2x

8.

Install terminal into socket housing. Refer to Table 8-7.

Figure 8-38. Fix Mechanics Wire to Socket Terminals

NOTE

For instructions on installing terminals, see APPENDIX B.2

6.

Obtain length of strong flexible wire for use as mechan-

MULTILOCK ELECTRICAL CONNECTORS, INSTALLING

ics wire. Feed wire through opening in socket terminal

SOCKET/PIN TERMINALS.

and then loop back twisting end until tightly coiled

9.

Connect front turn signal/auxiliary lamp connector.

around longer strand as shown in Figure 8-38.

10. Turn Ignition/Light Key Switch to IGNITION and test for

NOTE

proper operation and alignment. Adjust if necessary.

Be sure that mechanics wire is of sufficient strength to pull

11. Start two allen head screws to secure turn signal lamp to

terminal through conduit without breaking. Wire length must

mounting bracket. See Figure 8-32. Verify that conduit

also be long enough so that free end is not lost in conduit

fits in slot at back of bracket and is not pinched. Alter-

when pulled.

nately tighten screws to 36-60 in-lbs (4.1-6.8 Nm).

7.

Carefully pull wire to draw socket terminal through con-

12. Proceed as follows:

duit.

FLHT/C/U: Install connector on T-stud at top of left or

8.

Unravel mechanics wire to release socket terminal.

right fairing support brace (outboard side). Verify that

9.

Insert flare nut socket (Snap-on® FRX181) at bottom of

conduit is routed inboard using relief in upper outboard

turn signal mounting bracket and remove locknut from

corner of chrome skirt. Install outer fairing. See Section

stud. Remove the turn signal mounting bracket and

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

clamp block.

U), OUTER FAIRING/WINDSHIELD, INSTALLATION.

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f2322x8x

1

2

3

4

5

1.

Adjust headlamp high beam for proper height and lateral alignment.

2.

Locate left side auxiliary lamp relative to high beam centerlines.

3.

Locate right side auxiliary lamp relative to high beam centerlines.

4.

Adjust high intensity beam below and right of left side auxiliary lamp centerlines.

5.

Adjust high intensity beam below and right of right side auxiliary lamp centerlines.

Figure 8-39. Properly Aim Auxiliary Lamps

FLHR/C: Install headlamp assembly. See Section 8.11

ADJUSTMENT

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

LAMP ASSEMBLY, INSTALLATION.

13. Assemble auxiliary lamp, if necessary. See AUXILIARY

Headlamp High Beam

LAMP BULB, INSTALLATION, in this section.

1.

Adjust the headlamp high beam for proper height and

lateral alignment. See Section 8.11 HEADLAMP (FLHR/

C/S, FLHX, FLHT/C/U), HEADLAMP ADJUSTMENT,

AUXILIARY LAMP BRACKET

steps 1-10.

2.

With a rider seated on the motorcycle and the front

wheel pointed straight ahead, turn on the headlamp high

REMOVAL

beam.

1.

Remove auxiliary lamp bracket from motorcycle. Pro-

3.

Mark the center of the headlamp high beam by making a

ceed as follows:

vertical line through the horizontal line already drawn on

the wall. Properly adjusted, the beam should project an

FLHR/C: Remove acorn nuts from fork bracket studs.

equal area of light to the left and right of the vertical cen-

All Others: Loosen T40 TORX screws in upper and

terline. See item 1 in Figure 8-39.

lower fork brackets.

2.

Remove auxiliary lamp bracket from motorcycle.

Auxiliary Lamps

4.

Turn the headlamp off and move to the front of the

motorcycle.

INSTALLATION

5.

Measure the distance from the headlamp horizontal cen-

1.

Install auxiliary lamp bracket on motorcycle. Proceed as

terline down to the horizontal centerline of the left side

follows:

auxiliary lamp. Now measure the distance from the

headlamp vertical centerline out to the vertical centerline

FLHR/C: Slide slots of auxiliary lamp bracket onto upper

of the same lamp.

and lower fork bracket studs. Install acorn nuts on studs.

Alternately tighten acorn nuts to 72-108 in-lbs (8.1-12.2

6.

Repeat measurements performed in step 5 on right side

Nm) using a crosswise pattern.

auxiliary lamp.

All Others: Slide slots of auxiliary lamp bracket onto

7.

From the headlamp high beam centerlines, perform the

T40 TORX screws in upper and lower fork brackets.

measurements taken in steps 5-6 to locate the left and

Alternately tighten screws to 15-20 ft-lbs (20-27 Nm)

right side auxiliary lamp centerlines on the wall. See

using a crosswise pattern.

items 2 and 3 in Figure 8-39.

8-32

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TAIL LAMP ASSEMBLY

8.14

3.

Place tail lamp into position against chrome base.

TAIL LAMP/TAIL LAMP BULB

CAUTION

REMOVAL

Over tightening screws can crack the lense or result in

scratching of the fender paint.

1.

Remove two Phillips screws from lense to release tail

lamp assembly from chrome base. See left side of Fig-

4.

Install two Phillips screws and alternately tighten to 20-

ure 8-40.

24 in-lbs (2.3-2.7 Nm).

2.

Disconnect tail lamp connector [93], 4-place Multilock.

5.

Turn the Ignition/Light Key Switch to IGNITION and test

See right side of Figure 8-40.

lamp for proper operation.

3.

Rotate bulb socket 1/4 turn in a counterclockwise direc-

tion and remove from tail lamp assembly. Gently pull

bulb from socket.

CIRCUIT BOARD/CHROME BASE

INSTALLATION

REMOVAL

1.

Gently push new bulb into socket. Insert socket into tail

lamp assembly and rotate 1/4 turn in a clockwise direc-

1.

Remove two Phillips screws to release tail lamp assem-

tion.

bly from chrome base. See left side of Figure 8-40.

2.

Connect tail lamp connector [93], 4-place Multilock. See

2.

Disconnect tail lamp connector [93], 4-place Multilock.

right side of Figure 8-40.

See right side of Figure 8-40.

3

1

2

1.

Tail Lamp Assembly

2.

Chrome Base

3.

Tail Lamp Connector [93]

f2331x8x

Figure 8-40. Remove Tail Lamp and Depress Button to Release Socket Housing

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NOTE

[45]

[19]

f2172x8x

The rear fender tip lamp is present on FLHR and FLHT/C/U

[18]

models only. As the lamp is absent on FLHX models, the cir-

[93]

cuit board location is used for power to the license plate

[94]

lamps, a feature unique to that model. On FLHRC/S and

FLTR models, the location is unused.

4.

Remove Phillips screw (with captive washer) at center of

chrome base. Use both thumbs to push chrome base

upward until it becomes free of fender and then pull out

of fender hole.

5.

Feed socket housings through openings to inboard side

of chrome base. See Figure 8-41. For best results, free

the smaller socket housings first.

6.

Remove pin housing/circuit board from chrome base.

For best results, push index pins on pin housing from

holes in chrome base.

INSTALLATION

Opening

1.

Feed socket housings through openings to outboard

side of chrome base. See Figure 8-41. For best results,

[18] Left Turn Signal Lamp

feed the larger socket housings first.

[19] Right Turn Signal Lamp

2.

Fit bottom of chrome base into fender hole and then

[45] Fender Tip Lamp

push down to align center hole with clip nut on fender

[93] Tail Lamp

flange.

[94] Rear Fender Lights Harness

3.

Place pin housing over circuit board, if removed. See

Figure 8-43.

Figure 8-41. Rear Fender Lights Assembly

4.

Insert index pins at back of pin housing into holes in

chrome base.

CAUTION

Over tightening screw can crack the chrome base or

result in scratching of the fender paint.

f1506x8x

f1497b8x

Figure 8-42. Use Pick Tool to Release

Left Turn Signal Lamp Socket

H-D

USA

68830-98

3.

Disconnect remaining connectors. See Figure 8-41. To

release socket housings of left and right turn signal

lamps, use a pick or small screwdriver to depress button

Figure 8-43. Place Pin Housing Over Circuit Board

as shown in Figure 8-42.

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HOME

5.

Install Phillips screw (with captive washer) to secure pin

housing/circuit board and chrome base to clip nut on

f2329x8x

fender flange. Tighten screw to 40-48 in-lbs (4.5-5.4

2

Nm).

6.

Install socket housings into pin housing/circuit board.

Install rear fender tip lamp and both left and right turn

signal lamp sockets so that the release buttons are at

the top. Install the rear fender lights harness socket with

the button on the outboard side and the tail lamp socket

with the button at the bottom.

7.

To avoid stressing wires, verify that tail lamp conduit is

5

positioned on the outboard side of the rear fender tip

lamp and left turn signal lamp conduit as shown in Fig-

ure 8-40.

1

8.

Place tail lamp into position against chrome base.

1.43 Inch

(36.3 mm)

CAUTION

Over tightening screws can crack the lense or result in

scratching of the fender paint.

9.

Install two Phillips screws and alternately tighten to 20-

24 in-lbs (2.3-2.7 Nm).

10. Turn the Ignition/Light Key Switch to IGNITION and test

lamp for proper operation.

Right Side

REAR FENDER LIGHTS HARNESS

REMOVAL

0.88 Inch

(22.4 mm)

1.

Remove rear fender. See Section 2.34 REAR FENDER.

2.

Remove two Phillips screws to release tail lamp assem-

bly from chrome base. See Figure 8-40.

3

3.

Disconnect tail lamp connector [93], 4-place Multilock.

Set tail lamp assembly aside.

3

4.

Disconnect rear fender lights connector [94], 6-place

Multilock. Feed socket housing through opening to

inboard side of fender. See Figure 8-41.

4

5.

Release left and right rear turn signal lamp conduit from

1.

Adhesive Conduit

respective cable clip anchored on T-stud. On FLHX mod-

2.

Stud Plate

4.

Stamped Fender Clip

els, also release license plate lamps conduit from left

3.

T-Stud Cable Clips (2)

5.

Cable Strap

side cable clip. On FLHR and FLHT/C/U models, release

rear fender tip lamp conduit from both left side cable clip

Figure 8-44. Rear Fender Well

and stamped fender clip.

6.

Release rear fender lights harness from channel in stud

plate. Loosen two flange nuts, if necessary.

INSTALLATION

7.

Draw socket housing of rear fender lights connector [7],

1.

Proceed as follows:

8-place Multilock, through hole to inboard side of fender.

a. Thoroughly clean fender well with soap and water.

8.

Remove wire harness and adhesive conduit from fender

Do not use solvents or harsh chemicals or damage

well.

to painted surfaces may occur.

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FENDER TIP LAMPS

8.15

FRONT FENDER TIP LAMP

Front Fender Tip Lamp

Jumper Harness [32]

REMOVAL

1.

Insert blade of small screwdriver into slot at top of fender

tip lamp lense. Rotate end of screwdriver to unsnap

lense from lamp bracket.

2.

Holding Keps nuts at inboard side of rear fender, remove

two Phillips screws to release fender tip lamp bracket.

3.

Disconnect front fender tip lamp connector

[143],

2-

place Multilock. See Figure 8-47.

INSTALLATION

1.

Connect front fender tip lamp connector [143], 2-place

Multilock. See Figure 8-47.

2.

With wires routed along bottom left side, place fender tip

lamp bracket into position aligning holes in bracket with

those in fender.

f2356x8x

CAUTION

Figure 8-45. Inner Fairing (FLHT/C/U)

Over tightening screws can crack the bracket or result in

scratching of the fender paint.

3.

Slide Phillips screws through bracket and fender holes

and install Keps nuts. Holding nuts at inboard side of

fender, tighten screws to 20-24 in-lbs (2.3 - 2.7 Nm).

4.

Insert tab at bottom of lense into slot of fender tip lamp

bracket. Apply thumb pressure at top of lense until it

snaps into place.

5.

Turn the Ignition/Light Key Switch to IGNITION and test

lamp for proper operation.

FRONT FENDER TIP LAMP

JUMPER HARNESS

Front Fender Tip Lamp

REMOVAL

f2212x8x

Jumper Harness [32]

Used on FLHR Only

1.

Proceed as follows:

Figure 8-46. Headlamp Nacelle (FLHRC)

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

side of the steering head, disconnect the front fender tip

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

FLHR: Remove headlamp assembly. See Section 8.11

See Figure 8-45. Remove outer fairing only if necessary.

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

See Section

2.30 UPPER FAIRING/WINDSHIELD

LAMP ASSEMBLY, REMOVAL. Disconnect the front

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

fender tip lamp jumper harness connector [32], 2-place

REMOVAL.

Multilock. See Figure 8-46.

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2006 Touring: Electrical

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2.

Draw socket housing down to fender area.

1

f1505x8x

5

3.

Carefully cut cable strap to release front fender tip lamp

wires from brake caliper hose.

4.

Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see APPENDIX B.2

MULTILOCK ELECTRICAL CONNECTORS, REMOVING

SOCKET/PIN TERMINALS.

5.

Place the motorcycle on a hydraulic center stand with

the front wheel raised off the ground.

6.

Remove the front wheel. See Section

2.3 FRONT

2

WHEEL, REMOVAL.

3

7.

From inboard side of front fender, remove two nuts to

release trim strip from left side of fender. See Figure 8-

4

48.

1.

Fender Tip Lamp Bracket

2.

Tee Bolt

4.

Trim Strip

8.

Pull wires and socket terminals through grommet to

3.

Wire Conduit

5.

Oblong Hole

inboard side of fender. See Figure 8-49. Reaching under

left side of fender, draw wires forward out from beneath

fender bracket.

Figure 8-48. Install Conduit in Trim Strip

9.

Feed wires through oblong hole to outboard side of

fender.

Grommet

10. Insert blade of small screwdriver into slot at top of fender

tip lamp lense. Rotate end of screwdriver to unsnap

lense from lamp bracket.

11. Holding Keps nuts at inboard side of front fender,

remove two Phillips screws to release fender tip lamp

bracket.

f1504a8x

Socket

f1503b8x

Terminals

Figure 8-49. Pull Fender Tip Lamp Wires and Terminals

Through Fender Grommet

12. Disconnect front fender tip lamp connector

[143],

2-

Fender Tip

place Multilock, to release fender tip lamp assembly from

Lamp Bracket

jumper harness. See Figure 8-47.

Front Fender

INSTALLATION

Tip Lamp [143]

1.

Connect front fender tip lamp connector [143], 2-place

Multilock, to attach fender tip lamp assembly to jumper

Figure 8-47. Fender Tip Lamp Assembly

harness. See Figure 8-47.

2006 Touring: Electrical

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HOME

2.

Pull jumper harness conduit as close to fender tip lamp

connector [143] as possible, for the conduit is not easily

routed beneath the fender bracket.

3.

With conduit routed along bottom left side, place fender

tip lamp bracket into position aligning holes in bracket

with those in fender.

CAUTION

Over tightening screws can crack the bracket or result in

scratching of the fender paint.

4.

Slide Phillips screws through bracket and fender holes

and install Keps nuts. Holding nuts at inboard side of

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

f2392x8x

5.

Insert tab at bottom of lense into slot of fender tip lamp

bracket. Apply thumb pressure at top of lense until it

Figure 8-51. Install Cable Strap to Brake Hose

snaps into place.

6.

Route wire conduit inside trim strip and slide front tee

9.

Reaching under left side of fender, route wires of the

bolt over conduit. See Figure 8-48. Verify that second

jumper harness rearward between tee bolt nut and

tee bolt is in position at rear of trim strip.

fender bracket and then beneath fender bracket to grom-

7.

Feed socket terminals and wires through oblong hole to

met. See Figure 8-50.

inboard side of fender.

10.

Feed socket terminals and wires through grommet to

outboard side of fender. See Figure 8-49.

NOTE

Use the rearmost oblong hole as the front may be used for

1WARNING

installation of certain P&A accessories.

If any portion of the jumper harness is above the height

of the fender bracket, contact with the tire can cause

8.

While removing slack from wires on outboard side of

chafing or other damage. Damage to the wiring can lead

fender, align tee bolts with fender holes. Wtih trim strip

to loss of lighting while riding, which could result in

positioned against left side of fender, reach under fender

death or serious injury.

and install nuts on tee bolts. Alternately tighten nuts to

10-15 in-lbs (1.1-1.7 Nm).

11. Remove slack from wires on inboard side of fender. Ver-

ify that no portion of the jumper harness is above the

height of the fender bracket.

f2393x8x

12. Install terminals into socket housing.

NOTE

For instructions on installing terminals, see APPENDIX B.2

2

MULTILOCK ELECTRICAL CONNECTORS, INSTALLING

SOCKET/PIN TERMINALS.

13. Route socket housing upward behind chrome skirt

(FLHT/C/U) or through bottom of headlamp nacelle

(FLHR) to area beneath upper fork bracket. Connect

3

front fender tip lamp jumper harness connector [32].

5

4

1

NOTE

To connect jumper harness connector with the outer fairing

1.

Oblong Hole

installed (FLHT/C/U models), reach in below the fairing cap

2.

Jumper Harness

4.

Fender Bracket

on the left side of the steering head.

3.

T-Bolt Nut

5.

Grommet

14. Install the front wheel. See Section 2.3 FRONT WHEEL,

Figure 8-50. Left Side Front Fender Well

INSTALLATION.

8-40

2006 Touring: Electrical

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15. Install new cable strap to secure front fender tip lamp

wires to brake caliper hose. Cut any excess cable strap

material. See Figure 8-51.

16. Proceed as follows:

1

FLHT/C/U: Install outer fairing, if removed. See Section

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

U), OUTER FAIRING/WINDSHIELD, INSTALLATION.

FLHR: Install headlamp assembly. See Section 8.11

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

LAMP ASSEMBLY, INSTALLATION.

17. Turn Ignition/Light Key Switch to IGNITION and test

lamp for proper operation.

REAR FENDER TIP LAMP

2

f1501x8x

REMOVAL

4

1.

Remove two Phillips screws to release tail lamp assem-

bly from chrome base.

2.

Disconnect tail lamp connector [93], 4-place Multilock.

Set tail lamp assembly aside. See Figure 8-52.

3.

Disconnect rear fender tip lamp connector [45], 3-place

Multilock.

Rear Fender

Tail Lamp [93]

Tip Lamp [45]

3

f2390x8x

1.

Screwdriver

3.

TORX Screws

2.

Lense

4.

Fender Tip Lamp Bracket

Figure 8-53. Remove Rear Fender Tip Lamp Lense

and Bracket

4.

Feed socket housing through opening in chrome base to

inboard side of rear fender.

5.

Reaching under left side of rear fender, release conduit

from cable clip anchored on T-stud. Release conduit

from stamped fender clip.

Opening

f2172x8x

6.

Insert blade of small screwdriver into slot at top of fender

tip lamp lense. Rotate end of screwdriver to unsnap

Figure 8-52. Depress Button to Release Socket

lense from lamp bracket. See upper frame of Figure 8-

From Pin Housing

53.

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8-41

HOME

7.

Holding nuts at inboard side of rear fender, remove two

TORX screws to release fender tip lamp bracket. See

Fender

lower frame of Figure 8-53.

Hole

8.

Draw conduit and socket housing out through bottom

fender hole. See Figure 8-54.

9.

Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see APPENDIX B.2

MULTILOCK ELECTRICAL CONNECTORS, REMOVING

SOCKET/PIN TERMINALS.

INSTALLATION

1.

Place new fender tip lamp assembly next to discarded

Fender Tip

unit and cut wires to proper length.

Lamp Bracket

f1499x8x

2.

Crimp new socket terminals onto fender tip lamp wires.

Figure 8-54. Feed Fender Tip Lamp Socket and Conduit

NOTE

Through Fender Hole

For instructions on crimping terminals, see APPENDIX B.2

MULTILOCK ELECTRICAL CONNECTORS, CRIMPING

INSTRUCTIONS.

9.

To install tail lamp assembly, orient 4-place Multilock

3.

Install terminals into socket housing.

socket so that the release button is at the bottom and

insert into pin housing until it “clicks.” To avoid stressing

Table 8-8. Rear Fender Tip Lamps [45]

wires, verify that tail lamp conduit is positioned on the

outboard side of the rear fender tip lamp and left turn

Chamber

signal lamp conduit as shown in Figure 8-52.

Wire Color

Number

10. Place tail lamp into position against chrome base.

Black

1

Not Used

2

CAUTION

Black

3

Over tightening screws can crack the lense or result in

scratching of the fender paint.

NOTE

For instructions on installing terminals, see APPENDIX B.2

11. Install two Phillips screws and alternately tighten to 20-

MULTILOCK ELECTRICAL CONNECTORS, INSTALLING

24 in-lbs (2.3-2.7 Nm).

SOCKET/PIN TERMINALS.

12. Turn the Ignition/Light Key Switch to IGNITION and test

4.

Feed socket housing and conduit through bottom fender

hole. See Figure 8-54.

lamp for proper operation.

5.

Place fender tip lamp bracket into position aligning holes

in bracket with those in fender. Slide TORX screws

through bracket and fender holes and install nuts. See

lower frame of Figure 8-53.

6.

Insert tab at bottom of lense into slot of fender tip lamp

bracket. Apply thumb pressure at top of lense until it

snaps into place.

7.

Reaching under left side of rear fender, capture conduit

in cable clip anchored on T-stud. Capture conduit in

stamped fender clip next to fender hole.

8.

Feed socket housing through opening on left side of

chrome base to outboard side of rear fender. Oriented

with the release button at the top, insert socket housing

into pin housing/circuit board.

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2006 Touring: Electrical

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TURN SIGNAL LAMPS

8.16

BULB REPLACEMENT

[31R]

[31L]

REMOVAL

1.

Proceed as follows:

FLHR/C, FLHT/C/U: Remove two Phillips screws to

release lense from lamp. See Figure 8-55.

FLHRS, FLHX, FLTR: Insert blade of small screwdriver

into slot at bottom of lense. Gently rotate end of screw-

driver to unsnap lense from lamp.

2.

Push in bulb and rotate in a counterclockwise direction

to remove.

3.

Inspect condition of electrical contacts in socket. If nec-

essary, clean with a small wire brush and electrical con-

tact cleaner.

f2356x8x

INSTALLATION

1.

Liberally apply dielectric grease to contacts in socket

and at bottom of new bulb. For correct bulb type, see

Section 8.2 BULB CHART.

[31L] Left Front Turn Signal/Auxiliary Lamp

[31R] Right Front Turn Signal/Auxiliary Lamp

Figure 8-56. Inner Fairing (FLHT/C/U)

9462

2.

Push in new bulb and rotate in a clockwise direction to

install.

3.

Proceed as follows:

FLHR/C, FLHT/C/U: Seat lense in lamp and install two

Phillips screws.

FLHRS, FLHX, FLTR: Seat lense in lamp and gently

apply thumb pressure until it snaps into place. Rotate

lense to position slot at bottom of lamp.

4

FRONT TURN SIGNAL LAMP

5

3

FLHR/C, FLHT/C/U

1

REMOVAL

1.

Proceed as follows:

2

FLHT/C/U: Remove outer fairing. See Section

2.30

UPPER FAIRING/WINDSHIELD

(FLHX, FLHT/C/U),

1.

Turn Signal Lamp

OUTER FAIRING/WINDSHIELD, REMOVAL. Discon-

2.

Phillips Screw (2)

4.

Allen Head Screw (2)

nect the left or right front turn signal/auxiliary lamp con-

3.

Lense

5.

Mounting Bracket

nector [31L/R], 4-place Multilock, on T-stud at top of left

or right fairing support brace (outboard side). See Figure

Figure 8-55.

Front Turn Signal Lamp

8-56.

(FLHR/C, FLHT/C/U)

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HOME

NOTE

Front Turn Signal Lamps

For instructions on removing terminals, see APPENDIX B.2

Connector [31]

MULTILOCK ELECTRICAL CONNECTORS, REMOVING

SOCKET/PIN TERMINALS.

3.

Remove two allen head screws to release turn signal

lamp from mounting bracket. See Figure 8-55.

4.

Obtain three equal lengths of strong flexible wire for use

as mechanics wire. Feed wire through opening in socket

terminal and then loop back twisting end until tightly

coiled around longer strand as shown in Figure 8-58.

Repeat step with remaining socket terminals.

NOTE

Be sure that mechanics wire is of sufficient strength to pull

terminals through conduit without breaking. Wire lengths

must also be long enough so that free ends are not lost in

conduit when pulled.

f2212x8x

5.

Carefully pull wires to draw socket terminals through

both sections of conduit. For best results, pull one wire

at a time.

Figure 8-57. Headlamp Nacelle (FLHRC)

6.

Unravel mechanics wire to release socket terminals.

FLHR/C: Remove headlamp assembly. See Section

INSTALLATION

8.11 HEADLAMP

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

HEADLAMP ASSEMBLY, REMOVAL. Disconnect the

1.

Lay old turn signal lamp next to new turn signal lamp

front turn signal lamps connector [31], 6-place Multilock,

and cut wires to length.

anchored in hole of fork stem nut lockplate (left side).

See Figure 8-57.

2.

Strip 3/16 inch (4.8 mm) of insulation off new lamp wires

and crimp on new socket terminals.

2.

Remove appropriate terminal(s) from socket housing as

NOTE

follows:

For instructions on crimping terminals, see APPENDIX B.2

MULTILOCK ELECTRICAL CONNECTORS, CRIMPING

Table 8-9. Front Turn Signal Lamps [31]

INSTRUCTIONS.

FLHT/C/U, 4-Place

Left Side [31L]

Right Side [31R]

Wire Color

Chamber

Wire Color

Chamber

Mechanics Wire

Blue

1

Blue

1

Violet

2

Brown

2

Black

3

Black

3

NOTE: Terminal 4 is reserved for the auxiliary lamp.

FLHR/C/S, 6-Place

Left Side

Right Side

Wire Color

Chamber

Wire Color

Chamber

Socket Terminal

Blue (DOM)

4

Black

1

Violet

5

Brown

2

f1418x2x

Black

6

Blue (DOM)

3

Figure 8-58. Fix Mechanics Wire to Socket Terminals

8-44

2006 Touring: Electrical

HOME

3.

Reattach mechanics wire to socket terminals and care-

fully pull ends of mechanics wire to draw socket termi-

f2263x8x

nals back through conduit.

4.

Carefully remove mechanics wire to avoid damage to

6

terminals.

5.

Install terminals into socket housing. For correct terminal

4

locations refer to Table 8-9.

5

3

NOTE

7

For instructions on installing terminals, see APPENDIX B.2

MULTILOCK ELECTRICAL CONNECTORS, INSTALLING

8

SOCKET/PIN TERMINALS.

6.

Start two allen head screws to secure turn signal lamp to

2

mounting bracket. See Figure 8-55. Verify that conduit

9

5

fits in slot at back of bracket and is not pinched. Alter-

nately tighten screws to 36-60 in-lbs (4.1-6.8 Nm).

4

7.

Connect front turn signal/auxiliary lamp connector.

8.

Proceed as follows:

8

FLHT/C/U: Install connector on T-stud at top of left or

3

right fairing support brace (outboard side). Verify that

9

conduit is routed inboard using relief in upper outboard

corner of chrome skirt. See Figure 8-56. Install outer

1

fairing. See Section

2.30 UPPER FAIRING/WIND-

SHIELD (FLHX, FLHT/C/U), OUTER FAIRING/WIND-

SHIELD, INSTALLATION.

4.

Ball Stud

5.

Set Screw

FLHR/C: Install anchor on connector into hole of fork

6.

Left Bracket

stem nut lockplate (left side). See Figure 8-57. Install

1.

Right Lamp

7.

Left Lamp

headlamp assembly. See Section

8.11 HEADLAMP

2.

Right Bracket

8.

Lock Washer

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

3.

Jam Nut

9.

Acorn Nut

BLY, INSTALLATION.

9.

Turn Ignition/Light Key Switch to IGNITION and test for

Figure 8-59. Front Turn Signal Lamp Brackets (FLHRS)

proper operation.

6.

Remove two cable clips anchored in holes at bottom of

FLHRS

handlebar. Free turn signal lamp conduit from cable

REMOVAL

clips.

1.

Remove handlebar clamp shroud/wind deflector. See

7.

Remove acorn nut, lock washer and turn signal lamp

bracket from stem of mirror. Remove turn signal lamp

Section

2.32 WINDSHIELD/HEADLAMP NACELLE

(FLHR/C/S), NACELLE REMOVAL (FLHRS), steps 1-7.

assembly from motorcycle.

2.

Inside headlamp nacelle, locate the front turn signal

8.

If complete disassembly is required, proceed as follows:

lamps connector [31], 6-place Multilock, anchored in

Bracket Assembly

hole of fork stem nut lockplate (left side). See Figure 8-

57.

a. Using a 1/4 inch allen head socket, remove set

screw from turn signal lamp bracket. See Figure 8-

3.

Disconnect front turn signal lamps connector.

59.

4.

Remove appropriate terminals from socket housing.

b. Using a 3/16 inch ball allen, remove ball stud from

Refer to Table 8-9.

turn signal lamp housing.

NOTE

c. Remove jam nut from ball stud. Remove ball stud

For instructions on removing terminals, see APPENDIX B.2

from turn signal lamp bracket.

MULTILOCK ELECTRICAL CONNECTORS, REMOVING

SOCKET/PIN TERMINALS.

Socket/Isolator Assembly

5.

Carefully cut cable strap to release turn signal lamp con-

d. Push grommet at end of conduit into lamp housing.

duit from lower handlebar clamp. Draw free end of con-

Lightly lubricate grommet with glass cleaner, if nec-

duit out of headlamp nacelle.

essary.

2006 Touring: Electrical

8-45

HOME

e. Insert blade of small screwdriver into slot at bottom

of lense. Gently rotate end of screwdriver to unsnap

9409

lense from lamp.

f.

Push in bulb and rotate in a counterclockwise direc-

tion to remove.

g. Inserting blade of small screwdriver between outer

edge of rubber isolator and inside of lamp housing,

gently pry up socket assembly until free.

h. Pull socket assembly to draw conduit and terminals

into lamp and then out through lense opening.

i.

Remove rubber isolator from lamp if still installed.

Blind

Hole

INSTALLATION

NOTE

Figure 8-60. Front Left Turn Signal Lamps (FLHRS)

If turn signal lamp is already assembled, begin procedure at

step 2.

1.

Assemble front turn signal lamp as follows:

Socket/Isolator Assembly

a. Seat socket assembly in rubber isolator aligning tab

on socket with slot in isolator.

b. Feed terminals and conduit into lamp through lense

Pivot Pin

opening and then out through unthreaded hole.

Relief

c. Exercising caution to avoid pulling on wires, care-

fully pull grommet out through hole in lamp. For best

results, grasp edge of grommet with needle nose

pliers. Lightly lubricate grommet with glass cleaner,

if necessary.

d. Install socket assembly aligning tab on socket with

slot inside lamp.

9410

e. Using thumbs of both hands, apply even pressure

around outer edge of socket assembly until fully

Figure 8-61. Front Right Turn Signal Lamps (FLHRS)

seated.

f.

Liberally apply dielectric grease to contacts in

socket and at bottom of bulb. Push in bulb and

rotate in a clockwise direction to install.

3.

Slide turn signal lamp bracket onto stem of mirror and

g. Install lense in lamp and gently apply thumb pres-

install lock washer and acorn nut.

sure until it snaps into place. Rotate lense to posi-

tion slot at bottom of lamp.

NOTE

Bracket Assembly

Index pin at bottom of clutch lever bracket engages blind hole

h. Install ball stud into turn signal lamp bracket with the

at top of left turn signal lamp bracket to ensure proper orien-

ball end on the same side as the mirror stem hole.

tation. On the right side, location of the front brake lever pivot

i.

Thread jam nut onto ball stud until it contacts shoul-

pin relief prevents improper installation. See Figure 8-60 and

der.

Figure 8-61.

j.

Using a 3/16 inch ball allen, turn ball stud into turn

signal lamp housing until contact is made with jam

4.

Following bottom of handlebar, feed free end of turn sig-

nut.

nal lamp conduit into top of headlamp nacelle staying

k. Using a 1/4 inch allen head socket, start set screw

outboard of lower handlebar clamp.

into turn signal lamp bracket.

5.

Reaching inside headlamp nacelle, install terminals into

2.

If removed, install stem of mirror into hole in clutch lever

socket housing. For correct terminal locations refer to

bracket (left side) or master cylinder reservoir bracket

Table 8-9.

(right side).

8-46

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