dyna rear turn signal relocation kit - HARLEY
Contents
1. 12 Gently push the turn signal wires and connectors into the cavity inside the tail lamp housing Install the plastic plug into the tail lamp access hole in the rear fender 13 Capture the turn signal wires beneath the clips at the sides of the reinforcement bracket on the underside of the fender and at the back of the rear fender mounting bracket a Do not pull the turn signal wires tight against the fender edges or the turn signal relocation brackets b Check that there are no loose wires in the wheel compartment Adjust the wire routing if necessary 14 See Figure 3 Route the turn signal wire 2 along the underside of the relocation bracket 1 Tie the wire to the bracket just forward of the 90 degree bend with a cable strap 3 from the kit is05331 1 Relocation bracket 2 Turn signal wire 3 Cable strap Figure 3 Wire Routing Along Bracket NOTE Ambient temperature should be at least 60 F 16 for proper adhesion of the protective edging to the fender J04646 15 Use a mixture of 50 to 70 isopropyl alcohol and 30 to 50 distilled water to clean the bottom edge of the fender on each side at the point where the turn signal wiring crosses under the fender Allow to dry thoroughly Obtain the protective edging 8 from the kit and cut into two equal length pieces Carefully position the edging around the bottom edge of the fender and press firmly into place to prevent the turn signa2. 2 Not sold separately right side shown left opposite 3 Hex nut 2 7849 4 Lock washer 2 7042 5 Recess cover rubber 2 68749 09 6 Heat shrink tubing Not sold separately 6 inch 152 mm long 2 7 Cable strap 2 10065 8 Protective edging 68877 09 Items mentioned in text but not included in kit A Turn signal assembly 2 B Rearward attaching hardware from Saddlebag or Docking Hardware Kit Cc Original equipment forward attaching hardware 4 of 4
3. up to the lamp housing Allow 1 2 3 4 inch 13 19 mm of the tubing to remain covering the conduit For Wide Tire Installations Slide a second piece of shrink tubing over the connector end of the turn signal wires to cover the exposed colored wiring J04646 WARNING Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a e Avoid directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid directing heat toward any electrical system compo nent other than the connectors on which heat shrink work is being performed e Always keep hands away from tool tip area and heat shrink attachment 3 Use a heat gun or suitable radiant heating device to shrink the tubing to the wires and conduit 4 _Install the turn signal lamp wires through the small hole in the rubber recess cover and position the cover into the recess in the turn signal housing 5 Loosely install the hex nut 3 and lockwasher 4 onto the short threaded end of the turn signal relocation bracket 2 Assemble the turn signal lamp and recess cover onto the threads but do not fully tighten NOTE Check that the turn signal wires are not pinched and that the lockwasher will seat against the turn signa
4. cMOTOR HARLEY DAVIDSON WU J04646 INSTRUCTIONS REV 2008 06 26 DYNA REAR TURN SIGNAL RELOCATION KIT GENERAL Kit Number 68227 09 Models This kit is needed to complete the installation of a Saddlebag Kit or Docking Hardware Kit on specific model motorcycles Please see the P amp A Retail Catalog or the Parts and Acces sories section of www harley davidson com English only for model fitment information and the correct Saddlebag or Docking Hardware Kit part numbers Tools and Supplies Required An UltraTorch UT 100 HD 39969 Robinair Heat Gun HD 25070 with Heatshrink Attachment HD 41183 or other suit able radiant heating device is required for the proper installation of this kit A WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Contents See Figure 4 and Table 1 REMOVAL 1 Raise the vehicle on a motorcycle lift to allow access to the underside of the rear fender IWIN NIN To prevent accidental veh
5. icle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Refer to the service manual and remove the seat and disconnect the negative black battery cable from the negative battery terminal Retain all seat mounting hardware 3 See Figure 1 Remove the plastic plug 2 from the tail lamp access hole underneath the rear fender 1 J04646 is05268 Rear fender Plastic plug Tail lamp Socket head cap screw 3 Gray four way tail lamp connector Four way turn signal socket housing 2 1 2 3 4 5 6 Figure 1 Rear Lighting Connections 4 Carefully remove the turn signal wires and connectors from the inside of the tail lamp housing 3 Remove the turn signal wires from the clips underneath the fender Separate the four way turn signal socket housings from the rear lighting harness pin housings 6 5 Unplug the gray four way tail lamp connector 5 from the mating connector in the tail lamp housing NOTES Refer to AMP MULTILOCK CONNECTORS in the service manual for terminal removal procedures DO NOT remove the wires from the pin housings on the rear lighting harness 6 Note the wire colors and positions in each cavity of the socket housings leading from the turn signals Refer to the wiring diagram and the AMP MULTILOCK CONNEC TORS section in the service manual Remove the wires from both socket housings NOTE Use
6. l housing not the rubber recess cover 6 Align the relocation bracket with the rear of the fender support and fit the round pad into the mating hole in the support Follow the instructions in the Saddlebag or Docking Hardware Kit and use the specified hardware to install the rear fender mounting bracket 1 and turn signal relo cation bracket to the rear fender and vehicle frame fender support Tighten the brackets to the torque values indicated in those instructions 7 Align the turn signal housing so that the lens is aimed straight rearward for proper visibility While holding the turn signal housing in position tighten the hex nut and lock washer against the housing not the rubber recess cover to 96 120 in lbs 11 14 Nm 8 Repeat Steps 2 through 7 for the opposite side of the vehicle 9 Refer to AMP MULTILOCK CONNECTORS in the service manual for terminal installation procedures Install the turn signal wires and terminals into each cavity of the turn signal socket housings Refer to the service manual wiring diagram and the notes made earlier 10 Route the turn signal wires under the turn signal relocation bracket and under the rear fender edge on each side of the vehicle Connect the turn signal socket housings to the pin housings on the rear lighting harness 11 Plug the gray four way tail lamp connector on the rear lighting harness into the mating connector in the tail lamp housing under the fender 2 of 4
7. l wire from rubbing on the fender edge After pressing in place apply heat to the edging using a heat gun or radiant heating device held 3 6 inches 75 150 mm away from the edging for 10 15 seconds NOTE Allow AT LEAST 24 hours after applying the edging before exposing the area to vigorous washing strong water spray or extreme weather FINAL ASSEMBLY Verify that the ignition key switch is turned to the OFF position e Apply a light coat of petroleum jelly or corrosion retardant material to the negative battery terminal Refer to the ser vice manual connect the negative battery cable WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 2 Refer to the service manual and follow instructions to install the seat WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 3 Check the turn signals and the rest of the rear lighting for proper operation 3 of 4 SERVICE PARTS is05300 Table 1 Service Parts Figure 4 Service Parts Dyna Rear Turn Signal Relocation Kit J04646 Item Description Quantity Part Number 1 Rear fender mounting bracket 2 59542 09 2 Turn signal relocation bracket
8. the attaching hardware and follow the instructions found in the Saddlebag or Docking Hardware Kit to install the new fender mount brackets from this kit in place of the original equipment OE fender mount brackets To keep the fender aligned remove the OE bracket and com pletely install the new bracket on one side of the motorcycle before proceeding to the second side 1 of 4 7 See Figure 2 Remove the screw 2 at the front of the fender mounting bracket 1 NOTE The spacer 3 is glued to the fender and is not removed 8 Remove screw 4 and washer 5 at the rear of the fender mounting bracket Remove the turn signal lamp 6 sup port 7 and fender mounting bracket from the vehicle K 9 Ys is05283 ee Zs Co Va GO Turn signal lamp Turn signal lamp support 1 Fender mounting bracket 2 TORX screw 3 Spacer 4 Hex head screw 5 Washer 6 7 Figure 2 Remove Turn Signal Lamp from Fender INSTALLATION Turn Signal Installation NOTE The turn signal relocation brackets are side specific The brackets install with the support tube above the level of the fender support 1 ForWideTire Installations See Figure 4 Cut two pieces of shrink tubing 6 into two equal length pieces For All Other Models See Figure 4 Cut one piece of shrink tubing 6 into two equal length pieces 2 For All Models Slide one piece of shrink tubing over the turn signal wires all the way
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