Custom Auxiliary Lighting Kit Instruction Sheet - Harley
Contents
1. 4 Using butt splice connectors 18 from kit connect positive gray black wire and ground black wire from new lamp housing to same wires on 2 place Delphi connector cut from original lamp housing Refer to SEALED BUTT SPLICE CONNECTORS in Service Manual for instructions to splice wires FLHR FLHRS Models With Windshield NOTES FLHR and FLHRS models equipped with a windshield will require the separate purchase of Hardware Kit 69235 04 which includes three 1 1 2 in bolts and one 1 3 4 in bolt FLHRS models can be made windshield ready with the additional purchase of Hardware Kit 69234 04 which includes three 1 1 2 in bolts one 1 3 4 in bolt and four docking bush ings is01141 Lamp bracket Spacer 1 8 in Docking bushing Washer TORX screw FLHR 1 1 2 in FLHRS 1 3 4 in top left only Spacer 0 150 in FLHRS only P clamp existing Figure 7 Lamp Bracket Assembly FLHR S With Windshield Sr a NO 1 For FLHR models See Figure 7 Hold left side lamp bracket 1 in mounting position on motorcycle Install 1 8 in spacer 2 docking bushing 3 washer 3 and 1 1 4 in TORX screw 5 in top and bottom locations Tighten screws to 12 16 ft lbs 16 22 Nm Repeat for right side For FLHRS models See Figure 7 Hold left side lamp bracket 1 in mounting position on motorcycle Install 1 8 in spacer 2 docking bushing washer 3 and 1 1 4 in TORX screw 4 Pivot lamp bracket upward2. which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a J03729 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled 1 2003 Earlier Models a Remove seat according to the instructions in the Service Manual b Disconnect battery cables negative cable first Refer to BATTERY in Service Manual WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 2 2004 Later Models a Remove left side saddlebag Refer to SADDLEBAG REMOVAL in Service Manual b Remove left side cover and maxi fuse Refer to SYSTEM FUSES in Service Manual NOTE On 2006 and later Touring models equipped with Delphi 2 place connectors in each auxiliary lamp housing not spade terminals go to Step 3 On Touring models equipped with two spade terminal con nectors in each auxiliary lamp housing go to Step 4 3 See Figure 1 Remove original equipment auxiliary lamp 1 and bracket assembly 2 if equipped Refer to AUXIL IARY LAMPS in Service Manual Save sealed beams lens bulb assemblies
3. Install docking bushing 0 150 in spacer 5 clutch cable P clamp 3 of 6 6 washer 3 and 0 150 in spacer 5 Tighten screws to 12 16 ft lbs 16 22 Nm NOTE For right side use 1 8 in spacer 2 washer 3 and 1 1 4 in TORX screw 4 at top and bottom locations Tighten screws to 12 16 ft lbs 16 22 Nm 2 See Figure 9 Connect wires from lamp assembly to wires previously labeled or marked on motorcycle using butt splice connectors 18 from kit Refer to SEALED BUTT SPLICE CONNECTORS in Service Manual for instructions to splice wires NOTES When connecting wires from kit to existing wires match colors to colors i e purple wire to purple wire Splice into an existing black wire for kits with an additional ground Refer to appro priate wiring schematic if questions arise On 2006 and later FLHT models if using original lens bulb assemblies equipped with Delphi 2 pace connectors go to Step 3 If using auxiliary lamps with spade connectors go to Final Assembly subtopic 3 Cut both spade terminals from new accessory lamp as close to the terminal as possible 4 Using butt splice connectors 18 from kit connect positive gray black wire and ground black wire from new lamp housing to same wires on 2 place Delphi connector cut from original lamp housing Refer to SEALED BUTT SPLICE CONNECTORS in Service Manual for instructions to splice wires FLHRS Models Without Windshield 1 See Figure 8 Hold le
4. Lighting Kit Item Description Quantity Part Number 7 Stand off directional chrome 2 68821 00 Stand off directional black 2 73333 10 8 Lockwasher 5 16 in 2 7130W 9 Screw hex socket head 5 16 18 x 2 1 4 in 2 4296 10 Screw TORX button head 5 16 18 x 1 1 4 in 4 94602 98 11 Washer flat 7 16 in 4 57920 04 12 Ring nest 2 68331 02 13 Washer flat 3 8 in 2 6645 14 Cable tie 4 Not Shown 10181 15 Screw TORX button head 5 16 18 x 1 1 2 in Not Shown 4784 16 Spacer clamp Not Shown 65832 92 17 Sheathing black vinyl 2 Not Shown Not Sold Separately 18 Connector butt splice 12 Not Shown 70585 93 Items mentioned in text but not included in kit A Turn signal assembly left and right purchased separately J03729 6 of 6
5. See Figure 9 Install lamp housing 1 rubber washer 2 clamp block 3 and lamp bracket 4 Secure with lock washer 5 and nylon locknut 6 Tighten locknut to 14 18 ft lbs 19 24 Nm Repeat for other side Tie small knot in terminal end of gray wire from lamp housing 1 approximately 3 4 inches from terminal to avoid wire getting pulled too far into housing during installation See Figure 3 Insert bare end of gray wire through hole in mounting stud on auxiliary lamp housing 1 and through larger passage in lamp bracket until knot in terminal end of wire bottoms in socket housing 2 is01137 1 Auxiliary lamp housing 2 Socket housing Figure 3 Auxiliary Lamp Wire Routing 4 See Figure 9 Install turn signal assembly A to stand off 7 by routing wires through directional stand off and pas sage in lamp bracket 4 along side gray wire Figure 4 Secure turn signal assembly using lockwasher 8 and screw 9 Tighten to 96 120 in lbs 10 8 13 6 Nm Repeat for other side is01138 1 Gray wire to auxiliary lamp 2 Blue wire to parking lamp 3 Black wire to ground 4 Violet Brown wire to turn signal Figure 4 Turn Signal Wire Routing 5 See Figure 5 Install wire sheathing 1 onto wires 2 Insert a small amount of silicone into passage 3 of lamp 2of6 bracket and firmly slide sheathing into passage and allow to dry before installing 6 See Figure 9 After silic
6. and trim rings for kit installation 4 If using original auxiliary lens bulb assemblies cut off Delphi 2 place connector in original lamp housing about 2 inches from connector end Save connector with wire ends for later splicing to new lamp housing wires 5 See Figure 2 For FLHRS models Remove and discard original mounting screws 1 Repeat for other side Remove handlebar mounted turn signals acorn nuts internal tooth washers and mounting blocks from handlebars Install original acorn nuts and internal tooth washers to secure mirrors 6 Remove headlamp and headlamp bucket Refer to HEADLAMP in Service Manual NOTE Be sure to label or mark all wires before cutting them to confirm proper installation and function of kit Be sure to cut wires in places easily concealed for a clean kit installation 7 Locate turn signal connectors and auxiliary lamp con nectors Refer to ELECTRICAL CONNECTOR LOCA TIONS in Service Manual 8 Label cut and strip wires purple blue black and gray for auxiliary lamps prior to installing kit 1 of 6 Please dispose of materials responsibly is01134 1 Original equipment auxiliary lamp 2 Bracket assembly Figure 1 Original Equipment Auxiliary Lamp Assembly Typical is01135 Figure 2 Typical Mounting Screw Locations FLHRS ASSEMBLY NOTE The Custom Auxiliary Lighting Kit must be assembled before installation on motorcycle J03729
7. cMOTOR HARLEY DAVIDSON WY J03729 INSTRUCTIONS REV 2012 10 05 CUSTOM AUXILIARY LIGHTING KIT GENERAL Kit Number 69227 04A 68000043 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required Turn signal assembly must be purchased separately Use existing sealed beams lens bulb assemblies and trim rings if applicable Otherwise these parts can be purchased separately from a Harley Davidson dealer FLHR and FLHRS models equipped with windshield require the separate purchase of Hardware Kit 69235 04 FLHRS models can be made windshield ready with the additional purchase of Hardware Kit 69234 04 These kits are available from a Harley Davidson dealer 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 9 and Table 1 REMOVAL IWAN IN To prevent accidental vehicle start up
8. ect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 3 2003 Earlier Models a Connect battery cables positive cable first Refer to BATTERY in Service Manual b Install seat according to the instructions in the Service Manual 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 4 2004 Later Models a Remove left side cover and maxi fuse Refer to SYSTEM FUSES in Service Manual b Install left side saddlebag Refer to SADDLEBAG INSTALLATION in Service Manual 4of6 SERVICE PARTS is03870 Figure 9 Service Parts Custom Auxiliary Lighting Kit Table 1 Service Parts Custom Auxiliary Lighting Kit Item Description Quantity Part Number 1 Lamp housing auxiliary chrome 2 68822 04 Lamp housing auxiliary black 2 73340 10 2 Washer rubber 2 40901 05 3 Clamp block 2 69563 06 Bracket auxiliary lamp left side Not Sold Separately Bracket auxiliary lamp right side Not Shown Not Sold Separately 5 Lockwasher 3 8 in 2 7041 6 Locknut Nylon 3 8 in 2 7667 J03729 5 of 6 Table 1 Service Parts Custom Auxiliary
9. ft side lamp bracket 1 in mounting position on motorcycle Install 1 8 in spacer 2 washer 3 1 1 4 in TORX screw 4 Pivot lamp bracket upward Install 0 150 in spacer 5 into upper lamp bracket recess Install clutch cable P clamp 6 washer 3 and 1 1 2 in TORX screw 4 Tighten screws to 12 16 ft lbs 16 22 Nm NOTE For right side use 1 8 in spacer 2 washer 3 and 1 1 4 in TORX screw 5 at top location and bottom locations Tighten screws to 12 16 ft lbs 16 22 Nm 2 See Figure 9 Connect wires from lamp assembly to wires previously labeled or marked on motorcycle using butt splice connectors 18 from kit Splice into an existing black wire for kits with an additional ground Refer to SEALED BUTT SPLICE CONNECTORS in Service Manual for instructions to splice wires NOTE When connecting wires from kit to existing wires match colors to colors i e purple wire to purple wire Refer to appropriate wiring schematic if questions arise J03729 is01142 Lamp bracket Spacer 1 8 in Washer TORX screw FLHR 1 1 4 in Spacer 0 150 in P clamp existing Figure 8 Lamp Bracket Assembly FLHRS Without Windshield OO Nes Final Assembly sak See Figure 9 Connect and install lamp sealed beams lens bulb assemblies and trim rings using nest rings 12 from kit N Check all lighting components and switches function properly before operating vehicle WARNING Conn
10. one has dried place a cable tie 14 from kit approximately 1 inch from sealed area and clinch around sheathing to secure it in place is01139 ne 1 Wire sheathing 2 Wires 3 Lamp bracket passage apply silicone Figure 5 Install Wire Sheathing INSTALLATION FLHT Models 1 See Figure 6 Hold left side lamp bracket 1 in mounting position on motorcycle Install two TORX screws 2 and washers 3 into lamp bracket 1 and attach to motorcycle Tighten screws to 12 16 ft lbs 16 22 Nm Repeat for right side is01140 1 Lamp bracket 2 TORX screw 1 1 4 in 3 Washer Figure 6 Lamp Bracket Assembly FLHT 2 See Figure 9 Connect wires from lamp assembly to wires previously labeled or marked on motorcycle using butt splice connectors 18 from kit Splice into an existing black wire for kits with an additional ground Refer to SEALED BUTT SPLICE CONNECTORS in service manual for instructions to splice wires NOTES When connecting wires from kit to existing wires match colors to colors i e purple wire to purple wire Refer to appropriate wiring schematic if questions arise J03729 On 2006 and later FLHT models if using original lens bulb assemblies equipped with Delphi 2 pace connectors go to Step 3 If using auxiliary lamps with spade connectors go to Final Assembly subtopic 3 Cut both spade terminals from new accessory lamp as close to the terminal as possible
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