Custom Auxiliary Forward Lighting Kit Instruction - Harley
Contents
1. Pin connection position 6 yellow Pin connection position 7 gray Pen Pin connection position 8 black Figure 6 Fairing cap switch connections 3 See Figure 5 Bend up the flexible clamp 11 and place the auxiliary switch wires under flexible clamp and press clamp down onto wires From the kit find three new wire ties 10 and secure accessory and auxiliary switch wires together as shown 4 Check that rubber grommets 12 are installed on each side of fairing cap 1 Barbs on cap fit into holes in grom mets 5 Connect the fairing cap switch connector 105 12 place Multilock black on the right side of fairing cap 6 With the front forks turned to the left fork stop install fairing cap over ignition switch housing Check that grommets in fairing cap fully capture handlebar along with throttle and clutch cables 7 Start two T27 TORX screws with flat washers to fasten fairing cap to left and right sides of inner fairing Alternately tighten screws to 25 30 in Ibs 2 8 3 4 Nm 8 Refer to the appropriate Service Manual and assemble ignition switch 9 Install switch decal on switch J03966 Lamp Bracket Installation 1 See Figure 7 Hold left side lamp bracket 1 in mounting position on motorcycle Install two torx head screws 2 and washers 3 into lamp bracket assembly and attach lamp bracket to motorcycle Tighten to 12 16 ft lbs 16 22 Nm Repeat for right side is021422. Acquire 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 installation 1 of 5 Please dispose of materials responsibly is02138 Lamp bracket Directional standoff Directional assembly wires not shown Lock nut nylon Lock washer Washer Lock washer 5 16 inch Hex socket screw 5 16 18 Nest ring 10 Lamp housing 11 Washer 12 Screw Torx head 5 16 18 x 1 1 4 13 Rubber washer 14 Clamp block CON oar ena Figure 1 Auxiliary Lamp Assembly shown without wiring for assembly clarity is02139 2 Socket housing Figure 2 Lamp Wiring Routing Shown 3 See Figure 2 Insert bare end of grey wire through hole in mounting stud on lamp housing 1 and through larger passage in lamp bracket until knot in terminal end of wire bottoms in socket housing 2 J03966 is02140 Grey wire to auxiliary lamp Blue wire to parking lamp Black wire to ground Violet Brown wire to directional Po N Figure 3 Directional Wiring Routing Shown 4 See Figure 1 From the kit acquire directional stand off 2 hex socket screw 8 lock washer 7 and directional removed in step 4 5 Install directional assembly 3 to stand off 2 by routing wires through directional stand off and passage in lamp bracket 1 along side grey wire from step 3 Secure direc tion
3. 1 Lamp bracket 2 Torx head screw 1 1 4 inch 3 Washer Figure 7 Lamp Bracket Assembly left dide shown bare 2 Route and connect left and right turn signal wires from lamp assembly to left and right harness connectors according to procedure in appropriate Service Manual 3 Refer to the appropriate Service Manual and install outer fairing on motorcycle NOTE Be sure to test ALL functions of kit before operating motorcycle to confirm proper operation Refer to appropriate vehicle wiring schematic if in question 4 See Figure 1 Install lamp sealed beams and trim rings according to procedure in appropriate Service Manual using new nest rings 9 WARNING 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 5 Connect the battery cables positive cable first 6 Check the correct operation of all lighting components and switches before operating vehicle 4of5 SERVICE PARTS Figure 8 Service Parts Custom Auxiliary Forward Lighting Kit Table 1 Service Parts Table Item Description Quantity Part Number Item Description Quantity Part Number 1 Washer flat 4 57920 04 12 Bar Passing lamp RH not 68837 04A shown 2 Screw Torx socket button head 94602 98 13 Bar
4. Passing lamp LH 68836 04A 5 16 18 x 1 25 inch 4 3 Washer 2 6645 14 Nest ring pass fog pursuit lamps 68331 02 2 Washer lock 5 16 inch 2 7041 15 Isolator rubber 2 40901 05 Screw Torx socket button head 4296 16 Clamp block passing lamp 2 69563 06 5 16 18 2 6 Washer internal tooth lock 3 8 7130W 17 Switch spot lamp 71505 96 inch 2 7 Nut Nylon lock 3 8 16 UNC 2 7667 18 Terminal socket 20 16AWG 10 73191 96 not shown 8 Extruded vinyl tubing 0 38 inch 70561 90 19 Housing 4 way socket 2 not 73154 96BK dia 2 not shown shown 9 Cable tie 0 91 x 7 82 inch 6 10181 20 Bezel ring 2 68725 62A 10 Housing spot lamp chrome 2 68822 04 Bezel ring black 2 67700120 Housing spot lamp black 2 73340 10 21 Screw bezel 8 32 2 3514 11 Stand off directional chrome 2 68821 00 22 Nut bezel 8 32 2 7606 Stand off directional black 2 73333 10 23 Decal spotlight 15339 98 J03966 5 of 5
5. al assembly using lock washer 7 and hex socket head screw 8 Tighten to 96 120 in lbs 10 8 13 6 Nm Repeat for other side iso2141 Sa 1 Wire sheathing 2 Wires 3 Lamp bracket passage apply silicone Figure 4 Installing Wire Sheathing 6 See Figure 4 Install wire sheathing 1 onto wires 2 Insert a small amount of silicone into passage 3 of lamp bracket and firmly slide sheathing into passage and allow to dry before installing 7 After silicone has dried place a wire tie approximately 1 inch from the the siliconed area clinch around sheathing to retain it in place 8 Refer to appropriate Service manual and attach left and right turn signal connectors to turn signal wires 2of5 is02176 Fairing cap inner Fairing cap switch connector 105 12 place Multi lock black Auxiliary light switch Wire black ground Wire yellow Wire gray Fairing cap fastener screw holes N NO a Switch bracket screws 2 Switch bracket Wire ties 3 Flexible clamp Rubber grommets 2 Accessory switch Figure 5 Fairing Cap Inner Auxiliary Lamp Switch Assembly 1 Refer to the appropriate Service Manual and partially dis assemble ignition switch See Figure 5 Remove two T27 TORX screws with flat washers 7 to release fairing cap 1 from left and right sides of inner fairing With the front forks turned to the left fork stop
6. cMOTOR HARLEY DAVIDSON WY J03966 INSTRUCTIONS REV 2011 12 01 CUSTOM AUXILIARY FORWARD LIGHTING KIT GENERAL Kit Number 69818 06 68000042 Models This Custom Auxiliary Lighting Kit adds lamps and turn signals to 2006 and later FLHX model motorcycles Additional Parts Required This kit does not include turn signals You will be removing the original turn signals and re positioning them onto the new auxiliary mount This kit does not contain sealed beams See your local Harley Davidson dealer for your sealed beam lights 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 8 and Table 1 REMOVAL IWIN NIN 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
7. cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a Disconnect the battery cables negative cable first 2 Refer to the appropriate Service Manual and remove outer fairing from motorcycle 3 Locate and disconnect the left and right turn signal con nectors per procedure in appropriate Service Manual J03966 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Refer to the appropriate Service Manual and remove left and right turn signal wires from pin connectors Note loca tion of wires before removal 4 Remove original equipment turn signals per procedure in appropriate Service Manual and retain both left and right side turn signals NOTE Be sure to label or mark all wires before removing them to confirm proper installation and function of kit 5 Refer to appropriate Service Manual to locate turn signal connectors and auxiliary lamp connectors in preparation for auxiliary lamp kit installation Auxiliary Lamp Assembly NOTE The Auxiliary Lamp Kit will require basic assembly before installation on motorcycle 1 See Figure 1 Acquire lamp bracket 1 lamp housing 10 rubber washer 13 clamp block 14 lock washer 5 and nylon lock nut 4 and install lamp housing into lamp bracket Retain with lockwasher and lock nut Tighten to 14 18 ft lbs 19 24 Nm Repeat for other side 2
8. reach behind right side of fairing cap and disconnect the fairing cap switch connector 105 12 place Multilock black 2 from the wiring harness Remove fairing cap from motorcycle If wire ties are wrapped around the accessory switch wires remove wire ties and discard Remove two T25 TORX screws 8 to release switch bracket 9 from fairing cap Place auxiliary light switch 3 into the fairing cap left side switch position with switch light towards rear of motorcycle Route switch wires through switch bracket and position switch bracket over auxiliary switch Press switch bracket onto switch Install two T25 TORX screws 8 to secure auxiliary switch 3 to fairing cap 1 J03966 Auxiliary Switch Connection 1 See Figure 5 With the fairing cap inner positioned close to the motorcycle find the yellow 5 gray 6 and black 4 auxiliary switch wires NOTE The fairing cap switch connector 105 12 place Multilock black has numbers stamped into the secondary lock of the socket housing 2 See Figure 6 Position the fairing cap switch connector 105 12 place Multilock black 1 as shown Find the auxiliary switch black GRN wire and insert pin terminal into position 8 4 Find gray wire and insert pin terminal into position 7 3 Find yellow wire and insert pin terminal into position 6 2 3 of 5 is02178 1 Fairing cap switch connector 105 12 place Multilock black
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