PREMIUM AIR HORN INSTALLATION KIT - Harley
Contents
1. 19 8 mm O D 2 for 2007 and later models 6787 14 Screw hex socket button head 10 32 x 1 2 in 12 7 mm long with lock patch 3026 for 2007 and later models 15 Bracket horn mounting for 2007 and later models 69049 07 16 Locknut flanged 5 16 18 for 2007 and later models 7531 J03976 40f5 Table 1 Service Parts Horn Installation Kit Item Description Quantity Part Number Items mentioned in text but not included in kit A Horn Part Number 69423 05 includes item B e Tube air intake Part Number 59606 05 C Horn and enrichener bracket on 2004 2006 models D Mounting block on horn E T stud on isolator F Relay on horn harness J03976 5of52. from the kit as needed b Continue the long harness branch down behind the horn and enrichener bracket to the horn Plug the elbow terminal on the yellow wire into one of the ter minals on the underside of the horn c Plug the elbow terminal on the black wire of the main harness conduit into the remaining horn terminal d Referto BUTT SPLICE CONNECTORS in the service manual Connect the yellow black wire on the main harness conduit to the butt splice connector on the yellow black wire on the horn harness is02124 Main vehicle harness Horn Positive battery terminal Horn harness branch with black sleeve ring ter minal Fuse holder Horn relay PENA Do Figure 4 Horn Harness Routing NOTE To prevent possible damage to the electrical system verify that the Ignition Light Key Switch is in the OFF position before installing the battery cables 13 Verify that the Ignition Light Key Switch is in the OFF position J03976 IWIN NIN Connect 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 NOTICE Do not over tighten bolts on battery terminals Use recommended torque values Over tightening battery ter minal bolts could result in damage to battery terminals 00216a 14 Refer to the service manual and follow the i
3. Position the new engine center mounting bracket 3 over the holes and secure with the two 3 8 16 x 1 1 4 in long socket head cap screws 4 and hardened flat washers 5 from the kit Tighten the screws to 17 24 ft lbs 23 0 32 5 Nm J03976 Button head screw 2 Hole in engine cylinder head 2 Engine center mounting bracket 3 8 16 socket head cap screw 2 Hardened flat washer 2 Horn mounting bracket 10 32 button head screw 2 1 2 3 4 5 6 7 Figure 3 Engine Center Mounting Bracket 2007 and Later 6 Position the horn mounting bracket 6 over the engine center mounting bracket and secure with the two 10 32 x 1 2 in long button head screws 7 from the kit Tighten the screws to 36 60 in lbs 4 7 Nm New Horn Installation 7 See Figure 5 Obtain the horn mounting bracket 1 chrome hex head screw 2 and one large flat washer 3 from the kit Assemble the bracket to the slot in the horn bracket Item C or 15 with the bent tab toward the vehicle using the flanged locknut 16 and the second chrome flat washer 3 from the kit Do not fully tighten at this time Obtain the new isolator 5 and hex locknut 4 from the kit Insert the threaded stud on the isolator from the out side into the large hole in the horn mounting bracket Fit the three pins on the isolator into the small holes in the bracket and fasten the isolator to the bracket with the washer and nut Tighte
4. cMOTOR HARLEY DAVIDSON WY J03976 INSTRUCTIONS REV 2011 06 24 PREMIUM AIR HORN INSTALLATION KIT GENERAL Kit Numbers 69415 05A 69000035 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 A Premium Air Horn Part Number 69423 05 is needed for proper installation of these kits This item is available from a Harley Davidson Dealer AWARNING 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 Electrical Overload NOTICE It is possible to overload your vehicle s charging system by adding too many electrical accessories If the combined electrical accessories operating at any one time consume more electrical current than the vehicle s charging system can produce the electrical consumption can discharge the battery and cause damage to the vehicle s electrical system See an authorized Harley Davidson dealer
5. for advice about the amount of current consumed by addi tional electrical accessories or for necessary wiring changes 00211Cc AWARNING When installing any electrical accessory be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modi fied Exceeding the maximum amperage can lead to elec trical failures which could result in death or serious injury 00310a The Premium Air Horn requires up to 18 Amps additional cur rent from the electrical system when sounding the horn J03976 Kit Contents See Figure 5 and Table 1 INSTALLATION Original Horn Removal WARNING To prevent accidental vehicle start up 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 1 Refer to BATTERY DISCONNECTION AND REMOVAL in the owner s manual and follow the instructions given to disconnect the negative battery cable is02106 3 GY og ay Gs meat Horn Spade contacts on horn 2 Horn bracket Screw 2 5 Washer 2 Pons Figure 1 Original Equipment Horn Removal XL except 1200C 2 All XL models except 1200C See F
6. gth 20 Refer to the service manual and follow the instructions to install the seat 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 21 Test the horn for proper operation If the horn output is diminished sounds like a goose reverse the connections at the horn the positive and negative terminals are reversed 3 of 5 SERVICE PARTS is02100b a Figure 5 Service Parts Horn Installation Kit Table 1 Service Parts Horn Installation Kit Item Description Quantity Part Number 1 Bracket horn mounting 69472 05A 2 Cap screw hex head 5 16 18 x 7 8 in 22 2 mm long 94193 91T 3 Flat washer 0 59 in 15 mm O D 2 6781 4 Hex lock nut 5 16 18 with nylon insert 7739 5 Isolator 69471 05 6 Screw hex socket button head 1 4 20 x 1 2 in 12 7 mm long with lock patch 3063 7 Flat washer 0 44 in 11 2 mm O D 6220W 8 Wire harness horn 69200345 9 e Fuse blade type 20 amp yellow 72315 05 10 Cable strap 10 10006 11 Engine center mounting bracket for 2007 and later models 16353 04 12 Cap screw hex socket head 3 8 16 x 1 1 4 in 31 8 mm long 2 4748 for 2007 and later models 13 Flat washer hardened 0 78 in
7. igure 1 Remove the elbow terminals from the two spade contacts 2 on the horn 1 Remove the two button head TORX screws 4 and washers 5 that fasten the horn bracket 3 and upper stabilizer link bracket to the vehicle frame Remove the horn and horn bracket as an assembly which can be dis carded 1of5 Attach the upper stabilizer link bracket to the vehicle frame with the screws and washers and tighten to 25 35 ft lbs 33 9 47 5 Nm XL 1200C models See Figure 2 Remove the elbow ter minals from the two spade contacts 2 on the horn 1 and release the main harness conduit from the clamp 3 Remove the flanged locknut 5 and flat washer 6 to free the horn assembly from the horn and enrichener bracket 4 Remove the horn cover support bracket and rubber mount from the horn and enrichener bracket as an assembly The horn assembly flanged locknut and flat washer can be discarded is02107 Horn Spade contacts on horn 2 Horn wire clamp Horn and choke bracket Flanged lock nut Flat washer Omko Figure 2 Original Equipment Horn Removal XL 1200C NOTE DO NOT cut the elbow terminal from the black wire 3 Cut the elbow terminal from ONLY the yellow black horn wire on the main harness conduit For 2004 through 2006 models Proceed to Step 7 For 2007 and later models See Figure 3 Remove the two button head screws 1 from the holes 2 in the engine cylinder heads
8. n to 80 100 in Ibs 9 0 11 3 Nm NOTE Rotating the bracket as follows will verify that the horn will be aimed forward and down at a 45 degree angle for best sound dispersion 9 10 11 Rotate the horn mounting bracket clockwise tight against the horn and enrichener bracket Tighten the chrome hex screw to 80 100 in Ibs 9 0 11 3 Nm Obtain the Premium Air Horn Item A purchased separ ately and the socket head screw 6 and small chrome flat washer 7 from this kit Hook the mounting block D on the back of the horn over the T stud E on the isolator Line up the hole on the top of the mounting block with the threaded hole in the T stud Fasten the horn to the stud with the screw and washer Tighten to 100 120 in Ibs 11 3 13 6 Nm 2of5 NOTE On the underside of the horn note the small and markings at the terminals For use later but not as readily visible at that point New Horn Wiring 12 Obtain the horn wiring harness 8 from the kit Position the relay F on the harness with the electrical connector facing forward and down Use a cable strap 10 to attach the relay to the positive battery to maxi fuse wire con duit a See Figure 4 Bring the longest branch of the horn wiring harness upward and forward alongside the main harness 1 on the left side of the frame to a point directly above the new horn 2 Tie the horn harness to the main harness rearward of the horn with cable straps
9. nstructions given to attach the positive red battery cable and install the horn harness ring terminal with the red wire sleeve to the positive battery terminal 3 15 Bring the branch of the horn wiring harness with the ring terminal and black wire sleeve 4 over to the area of the ground stud on the left side of the crankcase next to the starter Remove the nut on the ground stud and install the ring terminal with the black sleeve to the stud Install the nut and tighten securely Follow the instructions in the service manual to attach the negative black battery cable to the right side ground stud on the crankcase 16 Tuck the fuse holder 5 and horn relay 6 into the avail able space alongside the battery 17 Refer to the service manual and follow the instructions to remove the seat 18 See Figure 5 Obtain the air intake tube B comes with Premium Air Horn Push the tube connector into the opening near the bottom of the horn until the tab retainer clicks into place NOTES Position the air intake tube so it will not get pinched by the seat after installation contact hot engine or exhaust components or interfere with the operation of the motorcycle Do not pinch the tube when fastening with cable straps 19 Route the tube upward to the area under the seat Tie the tube to the motorcycle with cable straps as needed Do not pinch the tube by over tightening the straps Cut off any excess tube or strap len
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