INSTRUCTIONS - Harley
Contents
1. 3 0f 5 FLHR FLHRS Models Using a Windshield NOTE FLHR and FLHRS models aready equipped with a wind Shield will also require hardware kit 69235 04 which con tains three 1 1 2 in long and one 1 3 4 in bolts FLHRS models can be made windshield ready by using hardware kit 69235 04 which contains three 1 1 2 in bolts one 1 3 4 in bolt and four docking bushings It will be necessary to utilize the 1 8 in spacer included in the passing lamp main kit for installation This spacer will be positioned on the lower mounting bolt between the nacelle and the docking bushing on motorcycles with windshield as seen in Figure 8 and on the lower mounting bolt between the nacelle and passing lamp bracket on motorcycles with out a windshield as seen in Figure 9 See Figure 8 On FLHT FLHR models the 150 in spacer 5 will not be used On FLHRS models install clutch cable P clamp 3 between washer and spacer as shown in Figures 8 and 9 1 For FLHR models hold left side passing lamp bracket 1 in mounting position on motorcycle Install 1 8 in spacer 7 bushing 6 washer 4 and 1 1 2 in torx head screw 2 in top and bottom locations Tighten to 12 16 ft lbs 16 22 Nm Repeat for right side See Figure 9 i06114c Passing Lamp Bracket Torx Head Screw FLHR 1 1 2 in 1 3 4 in for FLHRS top left only P Clamp existing part from motorcycle Washer Spacer 150 in FLHRS only Docking Bushing2. Remove handlebar mounted turn signals acorn nuts internal tooth washers signals mounting blocks from handlebars and install OEM acorn nuts and internal tooth washers to retain mirrors 3 Remove headlamp and headlamp bucket per procedure in appropriate Service Manual NOTE Be sure to label or mark all wires before cutting them to ensure proper installation and function of kit Be sure to cut wires in places easily concealed for a clean kit installation 4 Refer to approprioate Service Manual to locate turn sig nal connectors and passing lamp connectors Label cut and strip wires purple blue black and grey for passing lamps in preparation for passing lamp kit installation Assembly The Passing Lamp Kit will require basic assembly before installation on motorcycle 1 See Figure 3 Aquire passing lamp bracket 1 spot lamp housing 10 rubber washer 13 lock washer 5 and nylon lock nut 4 and Install spot lamp housing into passing lamp bracket Retain with lockwasher and lock nut Tighten to 14 18 ft lbs 19 24 Nm Repeat for other side J03102 Passing Lamp Bracket Directional Stand Off Directional Assembly wires not shown Lock Nut Nylon Lock Washer Washer Lock Washer 5 16 in Hex Socket Screw 5 16 18 x 2 1 4 in Nest Ring Spot Lamp Housing Washer Screw Torx Head 5 16 18 x 1 1 4 in Rubber Washer 1 2 3 4 5 6 7 8 9 Figure 3 Passing Lamp Assembly shown wit
3. 94602 98 4 Flat Washer 7 16 in ID 3 4in OD 57920 04 1 Clamp Spacer 65832 92 2 Rubber Washer 40901 05 Items in this kit are not sold separately J03102 1 OEM passing lamp 2 Bracket assembly Figure 1 0EM Passing Lamp Assembly typical WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate Service Manual proce dures 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 WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a 1of5 WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00049a 1 See Figure 1 Remove OEM passing lamp 1 and bracket assembly 2 if equipped per procedure in appropriate Service Manual Retain sealed beams and trim rings from OEM assembly for use in new passing lamp assembly i Py i d ji K Figure 2 Typical Mounting Screw Locations FLHRS Shown 2 See Figure 2 On FLHRS models Remove and discard original mounting screws 1 Repeat for other side
4. lt MOTOR2 HARLEY DAVIDSON NY J03102 INSTRUCTIONS REV 08 13 2004 Kit Number 69227 04 CUSTOM AUXILIARY LIGHTING KIT General This Custom Auxiliary Lighting Kit adds passing lamps and turn signals to 97 and later FLHT 94 and later FLHR and 04 and later FLHRS models NOTE A Service Manual for your model motorcycle is available from your Harley Davidson Dealer This kit does not include turn signals Turn signals must be purchased separately This kit does not contain sealed beams or trim rings Please see your local Harley Davidson dealer or use existing sealed beams and trim rings from motorcycle if equipped If your motorcycle is equipped with a windshield it will be necessary to purchase separately and use kit 69235 04 For windshield installation on stock FLHRS models it will be nec essary to purchase kit 69234 04 which includes windshield docking bushings QTY DESCRIPTION PART NO 2 Nest Ring 68331 02 1 Left Side Passing Lamp Bracket 68836 04 1 Right Side Passing Lamp Bracket 68837 04 2 Directional Stand Off 6882 1 00 2 Chrome Spot Lamp Housing 68822 04 4 Cable Ties 10181 2 Sheathing Black Vinyl Not Sold 2 Lock Nut Nylon 3 8 in 7667 2 Lockwasher 3 8 in 7041 2 Hex Socket Head Screw 5 16 18 x 2 1 4 in 4296 2 Lockwasher 5 16 in 7130W 8 Butt Splice Connectors 70585 93 2 Flat Washer 3 8 in ID 1 0 in OD 6645 1 Torx Head Screw 5 16 18 x 1 1 2 in 4784 4 Torx Head Screw 5 16 18 x 1 1 4 in
5. See Figure 9 On FLHT FLHR models the 150 in spacer 5 will not be used On FLHRS models install clutch cable P clamp 3 between washer and spacer as shown in Figures 8 and 9 1 See Figure 9 For FLHRS models without windshield mounting Hold left side passing lamp bracket 1 in mounting position on motorcycle Install 1 8 in spacer 6 washer 4 1 1 4 in torx head screw 2 Pivot pass ing lamp bracket upward Install 150 in spacer 5 into passing lamp arm Install clutch cable P clamp 3 washer 4 and 1 1 2 in torx head screw 2 Tighten to 12 16 ft lbs 16 22 Nm NOTE For right side use 1 8 in spacer 7 washer 4 and 1 1 4 in torx head screw 2 at top location and bottom locations Tighten to 12 16 ft lbs 16 22 Nm 2 Connect wires from passing lamp assembly to existing marked wires on motorcycle using butt splices from kit and splice wires according to procedure in appropriate Service Manual NOTE When connecting wires from passing lamp kit to existing motorcycle wires match colors to colors i e purple wire to purple wire Be sure to test ALL functions of kit before oper ating motorcycle to ensure proper operation Refer to appro priate vehicle wiring schematic if in question 4of 5 i06114b Passing Lamp Bracket Torx Head Screw FLHR 1 1 2 in P Clamp existing part from motorcycle Washer Spacer 150 in Spacer 1 8 in Figure 9 Passing Lamp Bracket Assembly le
6. Spacer 1 8 in Figure 8 Passing Lamp Bracket Assembly left side shown bare for clarity as installed on FLHR FLHRS models w windshield docking 2 For FLHRS models hold left side passing lamp bracket 1 in mounting position on motorcycle Install 1 8 in spacer 7 docking bushing 6 washer 4 and 1 1 2 J03102 in torx head screw 2 Pivot passing lamp bracket upward Install docking bushing 6 150 in spacer 5 clutch cable P clamp 8 washer 4 and 1 3 4 in torx head screw 2 Tighten to 12 16 ft lbs 16 22 Nm NOTE For right side use 1 8 in spacer 6 washer 4 and 1 1 2 in torx head screw 2 at top and bottom locations Tighten to 12 16 ft lbs 16 22 Nm 3 Connect wires from passing lamp assembly to existing marked wires on motorcycle using butt splices from kit and splice wires according to procedure in appropriate Service Manual NOTE When connecting wires from passing lamp kit to existing motorcycle wires match colors to colors i e purple wire to purple wire Be sure to test ALL functions of kit before oper ating motorcycle to ensure proper operation Refer to appro priate vehicle wiring schematic if in question 4 See Figure 3 Install sealed beams and trim rings according to procedure in appropriate Service Manual using new Nest Rings 9 5 Verify correct operation of all lighting components and switches before operating vehicle FLHRS Models not Using a Windshield NOTE
7. ft side shown bare for clarity as installed on FLHRS model without windshield docking 3 See Figure 3 Install sealed beams and trim rings according to procedure in appropriate Service Manual using new Nest Rings 9 4 Verify correct operation of all lighting components and switches before operating vehicle J03102 5 of 5
8. hout wiring for assembly clarity i06170 TRV Figure 4 Passing Lamp Wiring Routing Shown 2 Aquire grey wire from kit Tie small knot in terminal end of wire approximately 3 4 inches from terminal to avoid wire getting pulled too far into housing during installa tion 2o0f 5 See Figure 4 Insert bare end of grey wire through hole in mounting stud on passing lamp housing 1 and through larger passage in passing lamp bracket until knot in terminal end of wire bottoms in socket housing 2 See Figure 3 Aquire directional assembly 3 from kit directional stand off 2 hex socket screw 8 and lock washer 7 from kit i06171 Grey Wire to passing lamp Blue Wire to parking lamp Black Wire to ground Violet Brown Wire to directional Figure 5 Directional Wiring Routing Shown See Figure 5 Install directional assembly 3 from kit to stand off 2 by routing wires through directional stand off and passage in passing lamp bracket 1 along side grey wire from step 3 See Figure 3 Secure directional assembly using lock washer 7 and hex socket head screw 8 Tighten to 96 120 in Ibs 10 8 13 6 Nm Repeat for other side i06172 Wire Sheathing 2 Wires 3 Passing Lamp Bracket Passage apply silicone Figure 6 Installing Wire Sheating 6 See Figure 6 Install wire sheathing 1 onto wires 2 Insert a small amount of silicone into passage 3 of passing lamp bracket a
9. nd firmly slide sheathing into passage and allow to dry before installing After silicone has dried place a wire tie approximately 1 in from the the siliconed area clinch around sheathing to retain it in place J03102 Installation FLHT Models 1 Passing Lamp Bracket 2 Torx Head Screw 1 1 4 in 3 Washer Figure 7 Passing Lamp Bracket Assembly left side shown bare for clarity as installed on FLHT models 1 See Figure 7 For FLHT models Hold left side passing lamp bracket 1 in mounting position on motorcycle Install two torx head screws 2 and washers 3 into passing lamp bracket assembly 1 and attach passing lamp bracket to motorcycle Tighten to 12 16 ft lbs 16 22 Nm Repeat for right side 2 Connect wires from passing lamp assembly to existing marked wires on motorcycle using butt splices from kit Splice wires according to procedure in appropriate Service Manual NOTE When connecting wires from passing lamp kit to existing motorcycle wires match colors to colors i e purple wire to purple wire Be sure to test ALL functions of kit before oper ating motorcycle to ensure proper operation Refer to appro priate vehicle wiring schematic if in question 3 See Figure 3 Install passing lamp sealed beams and trim rings according to procedure in appropriate Service Manual using new Nest Rings 9 4 Verify correct operation of all lighting components and switches before operating vehicle
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