INSTRUCTIONS - Harley
Contents
1. tp cS AVIDSon MOTO 10 Figure 3b Zone Equivalents on the Compass Gauge Figure 3 J02461 2 of 4 Setting the Zone and Re calibrating the Compass CAUTION Upon initial power up of the compass after installation of the new sensor the gauge will continually spin until zone selection and calibration procedures have been success fully completed With the new sensor installed the compass must be adjust ed to operate in the zone in which it will be used Therefore the correct zone must again be programmed into the com pass See Figure 3a for locations within the lower 48 United States See Figure 4 for Canada and Alaska Hawaii is in zone seven Travel across several zones should not sig nificantly affect compass accuracy See Figure 3b The compass gauge display is used to indi cate the zone currently selected or stored in memory N indicates zone one is selected NNE indicates zone two and so on The compass must also be re calibrated after sensor replacement This allows the new sensor to compensate for the influence of the motorcycle structure in its determination of the correct heading i04899a eps Figure 4 Zone Chart for Alaska and Canada With Compass Gauge Equivalents Ss nw 15 nw 14 ww X 12130 A WSW Tep 10 ssw NOTE For Hawaii calibrate to Zone 7 SE Upon initial power up gauge will Turn accessory rocker switch ON continual2. and constant turning radius Continue driving until gauge displays the current direction about 60 seconds After the second calibration period If the calibration was valid the compass will begin to operate normally and show the current heading If the calibration was not valid the compass will continually spin If this happens perform the entire calibration procedure again Figure 5 Zone Selection and Re calibration Procedure J02461 3 of 4 The zone setting and re calibration of the compass can be accomplished by following the flow chart in Figure 5 e The re calibration procedure involves driving the motorcycle in large diameter circles 30 40 ft 9 12 M on level ground free of large buildings power lines etc e An on off sequence of the accessory rocker switch located on the inner fairing dash panel will set the zone and initiate re calibration e The quality of the calibration is directly dependent on the consistency of the circles driven during calibration e Two sets of equal size circles driven in opposite directions are required Please read through and understand the entire flow chart before starting the re calibration procedure Calibration information is stored in non volatile memory and re calibration will not be needed if power to the unit is dis connected However when travel to another zone intro duces noticeable inaccuracy the new zone should be stored in memory in or
3. cMOTOR2 HARLEY DAVIDSON WY J02461 General This kit is designed to service the compass sensor that comes with Electronic Compass Kit 74441 02 which fits 1996 and later FLHT Electra Glide and 1998 and later FLTR Road Glide model motorcycles Installation of the service sensor does not require disassembly of the fairing or fuel tank removal The service sensor harness will plug into the existing compass harness in the area under the seat The existing harness will be cut and a new Deutsch connector included in the kit must be installed See the Service Parts illustration for a list of items contained in this kit WARNING A Service Manual is necessary for installation of this kit The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper instal lation of this kit could result in death or serious injury NOTE A Service Manual for your model motorcycle is available from any Harley Davidson dealer Installation Removing the Existing Sensor WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the Owners Manual and follow the instructions given to remove the seat and disconnect the negative battery cable Retain all s
4. der to maintain compass accuracy MOTOR e Service Parts Part No 74633 02A Date 03 04 Electronic Compass Sensor Service Kit i05109 Item Description Quantity 1 Sensor electronic compass includes items 2 through 9 Socket housing 4 cavity Secondary lock 4 cavity Terminal socket 2 Plug seal pin 2 Pin housing 6 cavity Secondary lock 6 cavity Terminal pin 5 Plug seal pin Cable strap 6 0 19 x 7 5 in 5 x 190 mm Socket housing 6 cavity Secondary lock 6 cavity Terminal socket 5 Plug seal pin J02461 Part No Not sold separately 72114 94BK 72154 94 72191 94 72195 94 74106 98BK 74146 98 74190 98 74195 98 10006 74116 98BK 74156 98 74191 98 74195 98 4 of 4
5. eat mounting hardware 2 Remove the right side saddlebag Refer to SADDLE BAG REMOVAL in the appropriate Service Manual 3 Cut the wires on the old sensor a few inches away from the sensor CAUTION Do not use magnetic tools such as Torx drivers when installing the compass sensor If the compass bracket becomes magnetized it will affect calibration and accuracy INSTRUCTIONS REV 03 16 2004 Kit Number 74633 02A ELECTRONIC COMPASS SENSOR SERVICE KIT i04775 tif a Lower saddlebag guard Compass sensor Lower saddlebag guard screw Upper saddlebag guard screw Support bracket Support bracket screw and locknut Figure 1 Compass Sensor Mounting Model with Saddlebag Guards Shown 4 See Figure 1 Remove the outboard screw and locknut 7 attaching the existing sensor 3 and saddlebag sup port 1 to the support bracket 6 5 Remove the screw 4 and flat washer holding the upper part of the sensor bracket and the lower saddlebag guard 2 if so equipped to the support bracket Installing the New Compass Sensor Unit 6 Models WITHOUT Saddlebag Guards Attach the new compass sensor 3 to the support bracket 6 through the upper hole with the flat washer and screw 4 removed in Step 5 Models WITH Saddlebag Guards Attach the new compass sensor 3 to the lower saddlebag guard 2 and the support bracket 6 through the upper hole with the flat washer and screw 4 removed in Step 5 7 A
6. ll models Attach the compass sensor to the support bracket 6 and the saddlebag support 1 through the lower hole with the nut and screw 7 removed in Step 4 1 of 4 Routing the Compass Sensor Cable 1 See Figure 1 Remove the screw 5 fastening the com pass sensor cable clamp to the support bracket and pull the old cable from the clamp Insert the cable from the new compass sensor into the clamp and re fasten the clamp to the support bracket 2 Remove the old cable from the motorcycle as you lead the new cable up the right side saddlebag support bracket 6 and forward along the fender support brack et and frame strut Secure the new cable with cable ties from the kit at the same points as the old cable 3 Route the cable through the opening in the frame gusset under the turn signal security module if so equipped and behind the battery to the left side of the motorcycle 4 Run the cable along the left side of the battery Unplug the existing cable from the switched accessory connec tor located in front of the battery Plug the four position Deutsch connector from the new compass sensor into the accessory connector 105110 _ Open Orange White Figure 2 Connection Diagram Figure 3a Zone Chart for the Lower 48 States With Compass Gauge Equivalents Final Assembly In order to connect the new compass sensor to the compass display in the motorcycle fairing the old compass sens
7. ly spin until calibration is complete about Gauge spins to N indicating zone stored and calibration mode entered Turn ignition switch ON within 10 Quickly cycle the 3 sec J J accessory rocker switch 3 times ON OFF ON OFF ON OFF within 2 seconds Position the motorcycle on level ground in area free of large buildings power lines etc and prepare to drive in circles Reposition the motorcycle and prepare to drive in opposite direction 4 Turn accessory rocker switch ON Gauge spins to N indicating calibration mode is again entered immediately J 4 Zone selection mode entered Turn accessory rocker switch OFF Gauge stops spinning immediately J Determine correct zone per chart within 10 sec y Cycle the accessory rocker switch 1 time Start driving clockwise in consistent circles at constant speed and constant turning radius Continue driving until gauge displays S about 60 seconds ON OFF to advance one zone if needed within 10 sec Continue cycling the accessory rocker switch ON OFF until correct zone is displayed i02464a Start driving counterclockwise in consistent circles at constant speed
8. or harness must be cut in the area under the seat A six position Deutsch connector included in the kit will then be assembled to the front portion of the existing harness and plugged into the new sensor harness NOTE When cutting the existing harness make sure the wires from the front of the bike are long enough to reach the service harness connector without stretching pinching or rubbing 1 Cut the wires of the original compass sensor harness in the area under the seat so that the wires coming from the fairing will reach the service harness connector 2 Obtain the Deutsch socket terminals and related parts from the kit See a 1998 or later FLT Service Manual for Deutsch Solid Barrel Contact Crimping Instructions Follow instructions to terminate the wires from the old compass sensor harness 3 See Figure 2 Insert the terminals into the connector half as shown 4 Insert the seal pin in the unused cavity 5 Connect the old compass harness to the new sensor harness 6 Install the right side saddlebag Refer to SADDLEBAG INSTALLATION in the appropriate Service Manual 7 Refer to the Owners Manual and follow the instructions to re attach the negative battery cable and install the seat Awarninc After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a i04776c 4 or
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