Question about 2003 Harley Davidson FLHT Electra Glide Standard

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How to install ignition on flht harley using alignment tool

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  • Harley Davidson Master
  • 40,748 Answers

Hi Tinymoore, it's too bad you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below and good luck. Harley Davidson Manuals Mark Workshop

Posted on Jun 21, 2015

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Mitchy123
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SOURCE: 1999 harley davison

Are those air shocks ?

Posted on Oct 24, 2008

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SOURCE: Radio Harley FLHT 2005. The sound of the radio

Are you saying the radio gets louder as you go faster? If so, it is supposed to do that, and it is adjustable.

Posted on Jun 01, 2010

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2001 HD swingarm adjustments for reinstalling rear wheel


Hi, Anonymous what you really need is a service/owners manual sorry you can not find the first and best tool you ever bought for your Harley despair not, for a mere $10 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below, and for specific information or questions feel free to contact me at xlch@mail.com. Good luck and have a nice day.
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May 06, 2016 | 2001 Harley Davidson FLHT Electra Glide...

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I instaled a new key switch to my 04 superglide. then installed a new battery. now i have power through the electric side of the bike but cant turn key off. no fuel pump no start and headlights on bra


Probably not installed and aligned correctly.

To Re-Install the Ignition Switch

FIRST for DOMESTIC BIKES : Install the two screws with flat washers at the base of the ignition switch housing and alternately tighten those screws to 36-60 in-lbs (4.1-6.8 Nm). OR FOR INTERNATIONAL BIKES: Install two new break-away screws with flat washers as follows: verify that the threads in the upper fork bracket are clean and in good condition because dirty and/or damaged threads may cause the heads of the break-away screws to snap off before the switch housing is properly tightened. Use great care to avoid losing the heads of any of the break-away screws anywhere in the motorcycle because normal motorcycle operating vibrations could cause these heads to damage paint and other surfaces, wear away wire insulation or do other damage to the motorcycle and/or its parts. Tighten the break-away screws in a clockwise direction until the heads snap off. THEN install the handlebars. Then install the ignition switch connector which is a 3-place Packard connector, at the front of the ignition switch housing. THEN install the anchor of a new cable strap in the hole at the bottom right side of the radio and tighten the cable strap to capture and hold the main harness conduit to ignition switch.

ON FLHX and FLHT/C/U: Install the fairing cap next. THEN, using the elongated holes in the fairing brackets and a long ball end socket install the four socket head screws to fasten the radio (the storage box on an FLHT motorcycle) to the left and the right radio support brackets and alternatively tighten those screws to 35-45 in-lbs (4.0-5.1 Nm). THEN install the outer fairing.

ON FLTR:Install instrument nacelle next and then install the switch position plate fitting the tabs into the slots of the fairing cap on FLHX, FLHT/C/U or on FLTR the instrument nacelle. The plate will easily snaps into the proper place when the parts are correctly installed. Be careful not to break off the tabs and if you do damage them replace them. THEN install the spacer over the threaded post of the ignition switch housing until it contacts the switch position plate and arrange/locate the spacer so that the widest side is forward and the inside tabs fit into the post slots. THEN slide the collar over that threaded post until it comes up against the spacer and place the collar so that the outside tab is forward and the inside tabs fit into the slots of the post. THEN screw the nut onto the post with the lip facing down and the smaller Outside diameter facing up. THEN turn the front forks to the right fork stop and using a 7/8 inch open end adapter wrench to tighten the nut. It should be tightened top 125-150 in-lbs(14.1-16.9 Nm). THEN install the spring into the bore at the underside of knob the knob and with that knob oriented toward the "FORK LOCK" position, insert the shaft into the threaded post. THEN while pressing the knob down turn the key clockwise to "UNLOCK" and you should hear it click into proper engagement if it is correctly engaged after which you can release the knob into its normally installed position where it should correctly rotate through all four operating positions. If it does not install correctly as above verify that the button at the base/bottom of the knob is pressed in and the key is turned to a apposition 60 degrees beyond the "UNLOCK" position. Try to rotate it again and if it is still not installed properly do the foregoing steps again. If it still will not properly install it may be that the knob was not removed while in the "FORK LOCK" position or it may have inadvertently moved out of this position while the knob was removed. In this case you will need to get or make an alignment tool and insert it until it fits in where the lock mechanism would fit and then holding the forks so they cannot turn rotate the alignment tool in a counter clockwise directionuntil the fork locks at which time remove the tool and try to install again as set out above. If it will still not install properly thedetent and switch position lugs are likely not aligned properly which can occur if the alignment tool or the ignition switch knob is rotated before it is properly inserted or bottomed in the ignition switch housing. In this case reinstall the knob shaft into the threaded post and gently rotate the knob until it drops into a partially installed position and note where it is pointing at that time i.e. is it pointing to the rear, to the "ACCESS"," IGNITION" or "OFF" position and then again remove the knob and reinsert the alignment tool so that the bottom of the handle is about 0.500-0.0750 in. (12.7-19.1 mm) from the top of the threaded post, and then hold. It there and rotate the tool counter-clockwise as far as necessary to get it to the "FORK LOCK" position and then go through the foregoing installation procedures again. When it is properly installed you are done and can reinstall the main fuse and side cover etc.

Jun 25, 2014 | Harley Davidson FXD Dyna Super Glide...

1 Answer

How to re install the key switch on harley 2009 flhtcu


To Re-Install the Ignition Switch


FIRST for DOMESTIC BIKES : Install the two screws with flat washers at the base of the ignition switch housing and alternately tighten those screws to 36-60 in-lbs (4.1-6.8 Nm). OR FOR INTERNATIONAL BIKES: Install two new break-away screws with flat washers as follows: verify that the threads in the upper fork bracket are clean and in good condition because dirty and/or damaged threads may cause the heads of the break-away screws to snap off before the switch housing is properly tightened. Use great care to avoid losing the heads of any of the break-away screws anywhere in the motorcycle because normal motorcycle operating vibrations could cause these heads to damage paint and other surfaces, wear away wire insulation or do other damage to the motorcycle and/or its parts. Tighten the break-away screws in a clockwise direction until the heads snap off. THEN install the handlebars. Then install the ignition switch connector which is a 3-place Packard connector, at the front of the ignition switch housing. THEN install the anchor of a new cable strap in the hole at the bottom right side of the radio and tighten the cable strap to capture and hold the main harness conduit to ignition switch.


ON FLHX and FLHT/C/U: Install the fairing cap next. THEN, using the elongated holes in the fairing brackets and a long ball end socket install the four socket head screws to fasten the radio (the storage box on an FLHT motorcycle) to the left and the right radio support brackets and alternatively tighten those screws to 35-45 in-lbs (4.0-5.1 Nm). THEN install the outer fairing.


ON FLTR: Install instrument nacelle next and then install the switch position plate fitting the tabs into the slots of the fairing cap on FLHX, FLHT/C/U or on FLTR the instrument nacelle. The plate will easily snaps into the proper place when the parts are correctly installed. Be careful not to break off the tabs and if you do damage them replace them. THEN install the spacer over the threaded post of the ignition switch housing until it contacts the switch position plate and arrange/locate the spacer so that the widest side is forward and the inside tabs fit into the post slots. THEN slide the collar over that threaded post until it comes up against the spacer and place the collar so that the outside tab is forward and the inside tabs fit into the slots of the post. THEN screw the nut onto the post with the lip facing down and the smaller Outside diameter facing up. THEN turn the front forks to the right fork stop and using a 7/8 inch open end adapter wrench to tighten the nut. It should be tightened top 125-150 in-lbs (14.1-16.9 Nm). THEN install the spring into the bore at the underside of knob the knob and with that knob oriented toward the "FORK LOCK" position, insert the shaft into the threaded post. THEN while pressing the knob down turn the key clockwise to "UNLOCK" and you should hear it click into proper engagement if it is correctly engaged after which you can release the knob into its normally installed position where it should correctly rotate through all four operating positions. If it does not install correctly as above verify that the button at the base/bottom of the knob is pressed in and the key is turned to a apposition 60 degrees beyond the "UNLOCK" position. Try to rotate it again and if it is still not installed properly do the foregoing steps again. If it still will not properly install it may be that the knob was not removed while in the "FORK LOCK" position or it may have inadvertently moved out of this position while the knob was removed. In this case you will need to get or make an alignment tool and insert it until it fits in where the lock mechanism would fit and then holding the forks so they cannot turn rotate the alignment tool in a counter clockwise direction until the fork locks at which time remove the tool and try to install again as set out above. If it will still not install properly the detent and switch position lugs are likely not aligned properly which can occur if the alignment tool or the ignition switch knob is rotated before it is properly inserted or bottomed in the ignition switch housing. In this case reinstall the knob shaft into the threaded post and gently rotate the knob until it drops into a partially installed position and note where it is pointing at that time i.e. is it pointing to the rear, to the "ACCESS"," IGNITION" or "OFF" position and then again remove the knob and reinsert the alignment tool so that the bottom of the handle is about 0.500-0.0750 in. (12.7-19.1 mm) from the top of the threaded post, and then hold. It there and rotate the tool counter-clockwise as far as necessary to get it to the "FORK LOCK" position and then go through the foregoing installation procedures again. When it is properly installed you are done and can reinstall the main fuse and side cover etc.

May 29, 2014 | Harley Davidson FLHTCUI Electra Glide...

1 Answer

How to pull inner primary on 04 flht


Hi Bo, I'm sorry you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below: Good luck Harley Davidson Manuals Mark Workshop

Sep 25, 2011 | 2004 Harley Davidson FLHT - FLHTI Electra...

1 Answer

How do I install Ignition Switch Load on 2004 FLHT Electra Glide Standard ?


Hi Leaneralway, it's too bad you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below and good luck. Harley Davidson Manuals Mark Workshop

Jan 23, 2011 | Harley Davidson FLHT Electra Glide...

1 Answer

How do i install a FLHR headlight nacelle onto my FLHT?


Hi Martin, I'm sorry you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below: Good luck Harley Davidson Manuals Mark Workshop

Nov 15, 2010 | 2004 Harley Davidson FLHT - FLHTI Electra...

1 Answer

How to remove a ignition switch on a 2005 harley electra glide


You must have a special tool to maintain the alignment of the switch when you remove it. If not, you can't get it back on. I would suggest you take that to a shop.

Steve

Jun 18, 2010 | 2005 Harley Davidson FLHT - FLHTI Electra...

1 Answer

Sterring lock problem 2005 FLHT Harley Davidson


This is an active recall. Call a dealer, as long as your bike resides in the grouping of bikes, you will get a new ignition switch installed free of charge at no cost to you.

Jun 13, 2009 | 1991 BMW K 100 LT

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