BRAIDED SPARK PLUG WIRE KITS - Harley
Contents
1. and coil are protected against moisture 20f5 A Place the clips of the ground wire harness over the ferrules on the coil end of the plug wires a Remove one of the screws holding the coil to the nut plate Place the ring terminal of the ground wire harness over the screw Ensure that the prongs of the terminal are facing the plate N Replace the screw with the terminal into the coil and tighten WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 8 Connect battery cables to battery positive cable first Installation XLH Models Except for XL1200S WARNING To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the following procedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 1 Disconnect the battery cables negative cable first Awarnine Never disconnect a spark plug cable with the engine running If you disconnect a spark plug cable with the engine running you could receive an electric shock from the ignition system which could cause death or serious injury CAUTION When disc2. battery cables negative cable first before performing any of the following procedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 1 Disconnect the battery cables negative cable first WARNING Never disconnect a spark plug cable with the engine running If you disconnect a spark plug cable with the engine running you could receive an electric shock from the ignition system which could cause death or serious injury A WARNING To avoid personal injury do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components Gasoline is extremely flammable and highly explosive Follow all Service Manual instructions for proper assembly and disassembly procedures Failure to do this could result in death or serious injury Remove fuel tank following instructions in appropriate Service Manual Place tank in a safe location where it will not be damaged or scratched Set all fuel tank hardware aside for later reinstallation IMPORTANT NOTE When installing spark plug wires remove only one wire at a time and install the new braided wire that replaces it before moving on to the next wire As each original wire is removed check its length against each braided wire to find the corresponding braided wire that matches its length exactly i01596 A P
3. lt MOTORZ HARLEY DAVIDSON WY J01619 INSTRUCTIONS REV 5 99 Kit Numbers 31290 99A through 31296 99A 31965 93C through 31969 93C 31973 93C 32024 95B through 32027 95B 32036 95C through 32039 95C and 32063 98A BRAIDED SPARK PLUG WIRE KITS General These kits are designed for installation on these vehicles 1998 and later XL1200S 32063 98A 1986 and later XL models 31965 93C 31966 93C 31967 93C 32036 95C 32037 95C 32038 95C 32039 95C 1999 and later DYNA GLIDE models 31290 99A 31291 99A 31292 99A 31293 99A 31294 99A 31295 99A 31296 99A 1985 and later SOFTAIL and 1991 1998 DYNA GLIDE models 31968 93C 31969 93C 31973 93C 32024 95B 32025 95B 32026 95B 32027 95B Kit contents SOFTAIL and DYNA GLIDE QTY DESCRIPTION Cable Spark Plug Long Cable Spark Plug Short Strap Cable Ground Harness Clip Adhesive Backed a i ee eG 31965 93C 31292 99A and 31968 93C red with silver stripe 31966 93C 31291 99A and 31969 93C silver with black stripe 31967 93B 31290 99A and 31973 93C gold amp silver w black stripe 32038 95C 31294 99A and 32026 95B silver 32037 95C 31295 99A and 32025 95B red 32036 95C 31296 99A and 32024 95B blue 32039 95C 31293 99A and 32027 95B black Kit contents All XL s except XL1200S QTY DESCRIPTION 1 Cable Spark Plug Long 1 Cable Spark Plug Short 3 Strap Cable 1 Ground Harness 1 Clip Adhesive Backed Kit contents for XL1200S
4. QTY DESCRIPTION 2 Cable Spark Plug Long 2 Cable Spark Plug Short 6 Strap Cable 1 Ground Harness Left 1 Ground Harness Right 2 Clip Adhesive Backed NOTE Make note of the location of existing spark plug wires before disconnection Reference them when installing new wires Installation Dyna Models WARNING To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the following procedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 1 Disconnect the battery cables negative cable first WARNING Never disconnect a spark plug cable with the engine running If you disconnect a spark plug cable with the engine running you could receive an electric shock from the ignition system which could cause death or serious injury CAUTION When disconnecting spark plug cables always grasp and pull on the rubber boot at the end of the cable Do not pull on the cable itself as this could damage the cable 2 See Figure 1 Disconnect spark plug cables from coil and spark plugs Bf Rear cylinder ae fx 4 plug cable H E sdb lt k ms Figure 1 Dyna Spark Plug Cable Routing 3 Remove clip from horn bracket that secures front spark plug cable 1of5 IMPORTANT NOTE Rear spa
5. ble should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in personal injury 8 Connect battery cables to battery positive cable first J01619 5 of 5
6. lug wire retention kit Ignition coil Wire harness ground by Ring terminal od Figure 5 XL1200S Spark Plug Cables 2 See Figure 6 for spark plug wire routing Remove spark plug wire clips indicated These clips will be replaced with cable straps included in kit after wires are installed 3 Follow routing shown in Figure 6 and install spark plug wires Make sure boots are seated firmly on plugs and into the coil towers 4 Install cable straps at positions indicated in Figure 6 See Figure 5 Place the clips of the ground wire harness over the end ferrules of the plug wires NOTE As there are four spark plug cables there are two ground wire harnesses These two differ only in length 6 See Figure 4 Remove upper engine mount bolt and place both ring terminals over bolt 1 Remove and replace with cable strap 2 Remove and replace with cable strap 3 Remove and replace with cable strap 4 Remove do not reuse 5 Remove do not reuse Plug Wire Lengths approximate A 24 in B 21 in C 19 1 2 in D 20 1 2 in x0110x7x Figure 6 XL1200S Spark Plug Locations J01619 4of5 7 Install bolt with ring terminals and tighten to 30 35 ft lbs 41 47 Nm torque Mount ground wire harness wires to the frame with a clip Reassemble fuel tank to frame following Service Manual procedures Always connect the positive battery cable first If the positive ca
7. onnecting spark plug cables always grasp and pull on the rubber boot at the end of the cable Do not pull on the cable itself as this could damage the cable N See Figure 4 Disconnect spark plug cables from coil and spark plugs noting position of wires Remove rear wire from clip v Connect new braided spark plug cable to ignition coil and spark plugs Make sure boots caps are secured properly This will ensure that the connections to the plugs and coil are protected against moisture A Place the clips of the ground wire harness over the ferrules on the coil end of the plug wires a See Figure 4 Remove upper engine mount bolt and place ring terminal over bolt J01619 101594 10159 101593 Wire harness ground Ring terminal a Spark plug cables LE IN Ignition coil S clip Figure 4 XLH Spark Plug Wires Figure 4 XLH Braided Wire Mounting 6 Install bolt with ring terminal and tighten to 30 35 ft lbs 41 47 Nm torque 7 Mount ground wire harness wires to the frame with a clip Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in personal injury 8 Connect battery cables to battery positive cable first 3 of 5 Installation XL 1200S Models Awarnine To avoid accidental start up of motorcycle and possible personal injury disconnect the
8. rk plug cable goes to the top coil terminal 4 Connect new braided spark plug cable to ignition coil and spark plugs Make sure boots caps are secured properly This will ensure that the connections to the plugs and coil are protected against moisture a See Figure 2 Place the clips of the ground wire harness over the ferrules of the plug wires at the coil end For 1998 and Earlier Models 6 Remove one coil mounting screw and washer 7 Place the ring terminal of the ground wire harness over the screw Ensure that the prongs of the ring terminal are facing the washer The washer should be on the screw first followed by the ring terminal 8 Replace the coil mounting screw with the terminal and tighten For 1999 and Later Models Remove one coil bracket mounting nut N gt Place the ring terminal of the ground harness over the stud Ensure that the prongs of the ring terminal are facing the bracket Replace the coil bracket nut and tighten See Figure 1 Replace clip securing front cable to horn bracket Awarnine Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 10 Connect battery cables to battery positive cable first Installation Softail Models Awarnine To avoid accidental start up of motorcycle and possible personal inj
9. ury disconnect the battery cables negative cable first before performing any of the following procedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 1 Disconnect the battery cables negative cable first Awarnine Never disconnect a spark plug cable with the engine running If you disconnect a spark plug cable with the engine running you could receive an electric shock from the ignition system which could cause death or serious injury J01619 d0095x8x Electrical S Panel Coil Mounting Bracket Plug wires oO Washer j l D x Uf wn SE Wire harness oe a ground Ring terminal Figure 2 Dyna Braided Wire Ground Wire i01591 101592 Wire harness ground Ring terminal Ignition coil cover Spark plug cable Nut plate Ignition coil Lockwasher Figure 3 Softail Spark Plug Cables CAUTION When disconnecting spark plug cables always grasp and pull on the rubber boot at the end of the cable Do not pull on the cable itself as this could damage the cable 2 See Figure 3 Disconnect spark plug cables from coil and spark plugs Note the positions of the cables for reassembly 3 Connect new braided spark plug cable to ignition coil and spark plugs Make sure boots caps are secured properly This will ensure that the connections to the plugs
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