2001-2009 Harley Davidson Touring gauges & instruments


Harley Touring Gauges & Instruments

Need to fix your Harley Davidson H-D Touring bike? Visit the Home page to get the complete factory service manual for your 2001-2009 Touring motorcycle, and get it delivered to your computer in just seconds!


TOURING MODELS
 
2001 Harley Davidson Touring H-D Service Manual & 2001 H-D Electrical Diagnostics Manual for Harley Models: FLHTCUI Ultra Classic Electra Glide (2001), FLHTC/I Electra Glide Classic (2001), FLHT  Electra Glide Standard (2001), FLTR/I Road Glide (2001), FLHRCI Road King Classic (2001), FLHR/I Road King (2001) and also contains the 2001 H-D FLT Police Model Service Manual Supplement and 2001 H-D FLTRSEI2 Service Manual Supplement.
 
2002 Harley Davidson Touring Service Manual & 2002 H-D Touring Electrical Diagnostic Manual for models: FLHTCUI Ultra Classic Electra Glide (2002), FLHTC/FLHTCI Electra Glide Classic (2002), FLHT Electra Glide Standard (2002), FLHTCUI Ultra Classic Electra Glide (2002), FLTR/I Road Glide (2002), FLHRCI Road King Classic (2002), FLHR Road King (2002), 2002 FLT Police Models Service Manual Supplement and 2002 FLTRSEI2 Model Service Manual Supplement.

2003 Harley Davidson Touring 2003 H-D Touring Service Manual, 2003 H-D Electrical Diagnostics Manual, 2003 H-D Police Model Service Manual Supplement and 2003 H-D FLHRSEI2 Service Manual Supplement for: 2003 Harley-Davidson FLHTCUI Ultra Classic- Electra Glide, 2003 Harley-Davidson FLHR/FLHRI Road King, 2003 Harley-Davidson FLHT Electra Glide -Standard, 2003 Harley-Davidson FLHRCI Road King -Classic, 2003 Harley-Davidson FLTR/FLTRI Road Glide, 2003 Harley-Davidson FLHTC/FLHTCI Electra Glide- Classic, 2003 FLHP, FLHTP and FLHRSEI2.
 
2004 Harley Touring Service Repair Manual & Electrical Diagnostics Manual For: 2004 H-D FLT Police Model, 2004 H-D FLHTCSE, FLHRS/I Road King Custom (2004), FLHTCUI Ultra Classic Electra Glide (2004), FLHTC/I Electra Glide Classic (2004), FLHT/I  Electra Glide Standard (2004), FLTRI Road Glide (2004), FLHRCI Road King Classic (2004), FLHR/I Road King (2004).
 
2005 Harley Davidson Touring  Service Repair Manual & Electrical Diagnostics Manual For: FLHRS/FLHRSI Road King Custom (2005) FLHTCUI Ultra Classic Electra Glide (2005), FLHTC/FLHTCI Electra Glide Classic (2005), FLHT/FLHTI  Electra Glide Standard (2005), FLHTCUI Ultra Classic Electra Glide (2005), FLTRI Road Glide (2005), FLHRCI Road King Classic (2005), FLHR/FLHRI Road King (2005), 2005 H-D Touring Electrical Diagnostic Manual (800+ pages), 2005 FLT Police Models Service Manual Supplement and 2005 FLHTCSE 2 Model Service Manual Supplement.
 
2006 Harley Davidson Touring Motorcycle Service Manual for:  2006 FLHX Street Glide,  2006 FLHT Electra Glide Standard, 2006 FLHTC Electra Glide Classic, 2006 FLHTCU Electra Glide Ultra Classic, 2006 FLTR Road 2006 Glide, FLTRI Road Glide.
 
2007 Harley Davidson Touring Service Repair Manual & Electrical Diagnostics Manual For: (2007) FLHT Electra Glide Standard (2007), FLHR Road King (2007), FLHTC Electra Glide Classic (2007), FLHRS Road King Custom (2007), FLHTCU  Ultra Classic Electra Glide (2007), FLHRC  Road King Classic (2007), FLTR Road Glide (2007), FLHX Street Glide (2007).
 
2008 Harley Davidson Touring Motorcycle Factory Service Manual for: FLHT Electra Glide Standard, FLHR Road King, FLHTC Electra Glide Classic, FLHRC Road King Classic, FLHTCU Ultra Classic Electra Glide, FLHTCU ANV 105th Anniversary Ultra Classic Electra Glide, FLHRC ANV 105th Anniversary Road King Classic, FLTR Road Glide, FLHX Street Glide, 2008 FLT Police Models Service Manual Supplement, 2008 FLHTCUSE 3 Model Service Manual Supplement.
 
2009 Harley Davidson Touring Motorcycle Factory Service Manual for: 2009 FLHT Electra Glide, 2009 FLHTC/U Ultra Classic*Electra Glide with Side Car, 09 FLTR Road Glide, 09 FLHX Street Glide, 09 FLHR Road King Shrine, FLHRC Road King classic, FLHTC Electra Glide Classic.
 

GAUGES AND INSTRUMENTS  GENERAL

Use the troubleshooting tables in your service manual to diagnose and locate problems with malfunctioning or inoperative instruments and gauges. For wire connections at rear of gauges, see illistrations and photos in your manual for assistance. Refer to the applicable wiring diagram at the back of the book for further assistance.

DIAGNOSTICS

Fuel Level Gauge

When the Ignition/Light Key Switch is turned to IGNITION, the fuel gauge is connected to + 12 vdc. Current flows through the gauge and variable resistor in the fuel level sender to ground. The sender unit float controls the amount of resistance in the variable resistor.

Fuel Level Sender Test

See the following chart and “ground” the applicable test point.

1. Turn the Ignition/Light Key Switch to IGNITION. If gauge indicated FULL, gauge is functioning correctly. Proceed to step 3. If gauge did not indicate FULL, proceed to step 4.

2. With the Multi-Meter, Part No. HD-35500A, set on the RXI scale, measure the resistance of the sender unit. Place one probe on the center terminal and the other probe on a good ground.

3. The meter must indicate approximately 7-95 ohms on FLHT/C/U and FLTR models, 27-260 ohms on FLHR/C models.
a. If the fuel tank is full, the reading should be approximately 7-14 ohms on FLHT/C/U and FLTR models, 27-40 ohms on FLHR/C models.
b. An empty tank should have a 74-95 ohm resistance on FLHT/C/U and FLTR models, 240-260 ohm resistance on FLHR/C models.

NOTE: If a very high resistance or infinity is indicated on the meter, the sender may be “open” or not grounded. Verify that the sender and fuel tank are grounded by placing one probe of Multi-Meter on sender flange and the other probe on crankcase. Meter must indicate one ohm or less. Replace sender if one ohm or less was present. If a higher resistance is present, refer to applicable wiring diagram at rear of this manual and check sender ground circuit.

4. If gauge did not indicate FULL, use Multi-Meter to verify that 2-7 vdc is present at sender. If 2-7 vdc is not present, check for broken or disconnected wire or an open winding in fuel gauge. Replace gauge if winding is open.

Fuel Gauge: FLHR/C
Problem:
Gauge Faulty
Low Fuel Level Lamp: FLHTCU, FLTR
Problem:
Fuel low level lamp does not illuminate when fuel
level is low.
Low Fuel Level Lamp: FLHR/C
Problem:
Gauge Faulty
Perform resistance checks to determine if fuel gauge is faulty. Disconnect the gauge, remove the bulb and check for
resistance as follows:
441 +/- 20 ohms between the “S” and “G” studs
102 +/- 5 ohms between the “S” and “I” studs
Cause Solution
Lack of power.
Check for power (12 vdc or battery voltage) between pins 1
(positive) and 6 (negative). All checks are made at Low fuel
module connector [106].
No ground. Check for continuity to ground on pin 6.
Lamp defective or wiring broken.
Ground pin 2. If lamp illuminates, then LED is functional and
wiring is OK.
Defective module, insufficient voltage to module.
LED should illuminate when voltage at pin 4 exceeds 3.7
vdc.
Perform all checks at the gauge. Allow up to 30 seconds for the delay feature (both FLHR/C and FLHTCU). Orange is 12
volts DC. Pink is the sender. Black is ground. Pink to Black readings are listed below.
Key On Key Off
(Sender Disconnected)
Full
3 Volts 35 Ohms
1/4
6.4 Volts 153 Ohms (Low Light On)
Empty
7.3 Volts 215 Ohms
Oil Pressure Gauge and Indicator Light
Problem:
Low oil pressure light remains on with engine running
above idle and/or oil pressure gauge does not work.
Ambient Air Temperature Gauge
Problem:
Gauge inoperative.
Cause Solution
No oil pressure due to lack of oil or
faulty oil pump.
Running engine when OIL pressure light remains on and gauge indicates
low pressure will result in engine damage.
1. Check oil level. Add oil if low.
2. Restart engine and verify that oil pressure light goes off and gauge indicates
pressure. If problem still exists, refer to OIL PUMP in the FLT Service
Manual (Part Number 99483-01).
Contacts in pressure sending unit
not opening to shut off light.
Variable resistor in sender is
shorted to ground.
1. Locate the oil pressure sending unit on the front right side of the crankcase.
2. Verify that the electrical connector is properly connected to the sending unit.
3. If the oil pressure gauge indicates pressure but the low oil pressure light remains
on, proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Place one
ohmmeter probe on indicator lamp terminal (closest to latch), place the other
probe on the crankcase. Meter must read zero ohms.
b. Start the engine and run at a fast idle. The ohmmeter must read infinity.
c. Replace the sending unit if the above meter readings are
not
obtained.
4. If the low oil pressure light functions correctly, but the pressure gauge does not,
then proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Turn the Ignition/
Light Key Switch to IGNITION. The gauge must read zero.
b. Ground BN/GN wire terminal to crankcase. The gauge must read full scale 70
PSI.
c. Replace the sending unit if the above gauge readings are obtained. If the
gauge readings are
not
obtained, then replace the pressure gauge.
No power to gauge. See Voltmeter.
CAUTION
Cause Solution
Sensor not grounded or open
between sensor and gauge.
Test for continuity between pin 1 and ground and pin 3 and gauge. Repair if open.
Broken or disconnected power or
ground wire to gauge.
Check for 12 vdc between pins 1 and 3 at connector [115A]. Replace gauge if voltage
is present. Use voltage drop tests and continuity checks to isolate if voltage is not
present.
Malfunction in gauge or sensor.
Measure resistance between pins 1 and 3 at 65° to 85° F. Resistance should be 43-31
ohms. Replace sensor if out of range, replace gauge if within range.

Harley Touring Service Manual, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 01, 02, 03, 04, 05, 06, 07, 08, 09 Repair Guide, Owners Service Manual, Harley Davidson Manuals, Handbook, Book, Repair Information, Specifications, Specs, Gauge Specs, Sensor wire colors, Gauge replacement.